Standards, Training, and Certification in the Bridge IndustryPresented by: Derrick Castle; BCI, PCS;

KYTC

Introduction• The purpose of this webinar is to describe how to properly

specify a coating system for a specific substrate (steel, metal, previously coated), structure and environment by specifying specific industry standards, training and certifications to ensure a quality project.

What is a Specification?• A detailed coating specification is a

complex and sometimes confusing document to navigate. Yet, it is the rulebook for QC and QA personnel responsible for inspecting work.

Specification

• Each coating specification for a steel structure should start with:– SSPC Technical Insight Report:

Preparing and Using Protective Coating Specifications

– SSPC PA 1

SSPC Technical Insight Report: Preparing and Using Protective Coating Specifications

• The purpose of this report is to describe some best practices for preparing and administering a quality specification for application of high performance protective coatings and linings for the bridge industry.

SSPC-PA 1

• SSPC-PA 1, Shop, Field, and Maintenance Painting of Steel

SSPC Guide 12

• Guide for Illumination of Industrial Painting Projects

• This guide provides information on the quantity and quality of lighting on industrial painting projects that is conducive to achieving quality surface preparation and coating application, productivity, inspection/quality control, and accident prevention.

SSPC Guide 12

Work Area Minimum Recommended

General Work 10 Foot Candles 20 Foot Candles

Surface Preparation and Coating Application

20 Foot Candles 50 Foot Candles

Inspection 50 Foot Candles 200 Foot Candles

Surface Preparation

• Dual Purpose: Cleaning the surface Roughening the surface

SSPC Guide 15

• Field Methods for Extraction and Analysis of Soluble Salts on Steel and Other Nonporous Substrates

• This Guide describes the most commonly used field methods for the extraction and analysis of soluble salts on steel and other nonporous substrates. Laboratory methods are only included for situations where more complete salt extractions are desired through rigorous laboratory retrieval and analysis protocols.

Surface Cleanliness Standards

• SSPC and NACE issue consensus standards• Currently SSPC has issued 13 cleanliness standards• NACE is jointly referenced in 7 of the 13

SSPC-SP1, Solvent Cleaning• Requires the removal of all visible grease, oil,

lubricants, cutting compound and other non-visible contaminants from the surface

• Degreasing agents (solvents, alkaline and emulsion cleaners, steam cleaning) described earlier

• Mechanical cleaning will not remove grease/oil • “Indirect requirement” to the SSPC surface

cleanliness standards

SSPC-SP2, Hand Tool Cleaning

• SSPC-SP1 (solvent cleaning) is an “indirect requirement”• Requires removal of all loosely adhering rust, mill scale

and paint• Remaining materials must be tightly adhering • Contract may require feathering • No surface profile requirement

SSPC-SP3, Power Tool Cleaning

• Requires removal of all loosely adhering rust, mill scale and paint

• Remaining materials must be tightly adhering (dull putty knife test)

• No surface profile requirement

SSPC-SP11, Power Tool Cleaning To Bare Metal• Requires:

Removal of all loosely and all tightly adhering mill scale, rust and paint to expose the bare metal surface (traces of paint, rust and mill scale can remain in bottom of pits)

A minimum 1 mil anchor pattern

• Prepared surfaces should not be compared to abrasive blast cleaned surfaces Surface roughness characteristics are different

SSPC-SP15, Commercial Grade Power Tool Cleaning• Requires removal of all loosely and tightly adhering

mill scale, rust and paint• Staining from rust, paint and mill scale permitted

but must not exceed 33% (one third) of each 9 in2 of prepared surface

• Traces of paint, rust and mill scale can remain in bottom of pits

• Minimum 1 mil anchor pattern

Power Tool Cleaning-General• SSPC-SP1 (solvent cleaning) is an “indirect

requirement” of SP3, SP11, SP15• Weld slag, flux and fume deposits should be

removed from welds (per contract documents)• Verify removal of dirt/debris generated by power

tool cleaning (blow down, brush, vacuum)– If blow down, verify cleanliness of compressed air

(“indirect requirement” of SP3, SP11, SP15)

SSPV VIS 3

• Excellent tool to “calibrate” eye and aid in establishing project standard

Abrasive Blast Cleaning Standards• Listed from lowest

to highest level of cleanliness required

• Specification must stipulate the required depth of the surface profile

• SSPC-SP7/NACE 4• SSPC-SP14/NACE 8• SSPC-SP6/NACE 3• SSPC-SP10/NACE 2• SSPC-SP5/NACE 1

Dry Abrasive Blast Cleaning• Selecting the correct type and size of abrasive

Too small abrasive – surface profile too shallow Too large abrasive – surface profile too deep Test abrasive size selected prior to production

for surface profile yield

Blast Cleaning Abrasives• Two broad categories– Expendable (used once

and then discarded)– Recyclable (breakdown

rate is low, permitting multiple use)

Specifications for Mineral & Slag Abrasives

• SSPC AB 1, Mineral and Slag Abrasives• SSPC AB 2, Cleanliness of Recycled Ferrous

Metallic Abrasives• SSPC AB 3, Ferrous Metallic Abrasive• SSPC AB 4, Recyclable Encapsulated Abrasive

Media(in a compressible cellular matrix)

SSPC-SP7/NACE No. 4, Brush-off Blast Cleaning• “Brush blasting” the surface• Removal of all loosely adhering materials• Remaining materials tightly adhering, dull

putty knife test• Contractor must exercise care if roughening

existing coating

SSPC-SP14/NACE No. 8,Industrial Blast Cleaning• Requires removal of all loosely adhering rust, mill scale

and paint and removal of 90% of all tightly adhering materials

• Evenly distributed islands of intact mill scale, rust or paint (up to 10%) may remain*

• Staining is unlimited• Project specification may invoke feathering of remaining “islands” of coating

*Remaining materials tightly adhering per dull putty knife test

SSPC-SP6/NACE No. 3, Commercial Blast Cleaning

• Requires removal of all loosely and all tightly adhering mill scale, rust and paint

• Staining from rust, paint and mill scale permitted• Staining cannot exceed 33% (one third) of each 9 in2

of prepared surface

SSPC-SP10/NACE No. 2, Near-White Blast Cleaning

• Requires removal of all loosely and all tightly adhering mill scale, rust and paint from the surface

• Staining from rust, paint and mill scale permitted

• Staining cannot exceed 5% of each 9 in2 of prepared surface

SSPC-SP5/NACE No. 1,White Metal Blast Cleaning

• No loosely or tightly adhering materials may remain

• No staining is permitted

SSPC VIS 1

• Excellent tool to “calibrate” eye and aid in establishing project standard

SSPC/NACE Waterjetting Standards

• SSPC-SP WJ-1/NACE WJ-1, Clean to Bare Substrate

• SSPC-SP WJ-2/NACE WJ-2, Very Thorough Cleaning

• SSPC-SP WJ-3/NACE WJ-3, Thorough Cleaning• SSPC-SP WJ-4/NACE WJ-4, Light Cleaning

Water Jetting - General

• Water jetting cannot generate surface profile (can restore existing profile)

• If surface profile required, alternative surface preparation methods are required

• Wet abrasive blast cleaning can generate surface profile

Water Jetting - General

• Establish project-specific cleanliness standards• Visual verification using SSPC VIS 4/NACE VIS 7 or

SSPC VIS 5/NACE VIS 9– Prepared surfaces rarely match visual guides– Excellent tool to “calibrate” eye and aid in establishing

project standard– Use described later

Evaluating Flash Rusting

• SSPC VIS 5/NACE VIS 9 illustrates 3 levels of flash rusting:

– Light (L)– Medium (M)– Heavy (H)

• NSRP Flash Rust Guide

SSPC Paint Application Standards• SSPC-PA 2, Procedure for Determining

Conformance to Dry Coating Thickness Requirements

• SSPC- PA 17, Procedure for Determining Conformance to Steel Profile/Surface Roughness/Peak Count Requirements

QP Certifications

What is QP Certification?• A proven way for facility owners and specifiers

to evaluate contractor capabilities to perform quality blasting and application work for coating projects

• Certified contractors will have the experience, knowledge and equipment to produce high quality work

Why Certified Contractors?• Certified contractors are experienced with a

demonstrated history and competence on protective coatings projects.

• Assurance that projects will be completed within your specifications.

• Lower risks of safety, health, and costly environmental compliance violations.

Types of SSPC QP Certification• QP 1 – Field Application of Coatings• QP 2 – Field Removal of Hazardous Coatings• QP 3 – Shop/Fixed Coating Operations

SSPC Training and Certification Programs for the Bridge

Industry

Training/Certification Programs

A joint standard of SSPC/NACE designed to certify craft workers who have experience and training on all aspects of surface prep and coating application.

Coating Application Specialist (CAS)

Training/Certification Programs

Contractor worker training that covers surface preparation, cleanliness, profile, and abrasives. Course includes exam, equipment setup, abrasive blasting, and safety meeting.

Abrasive Blasting Program (C7)

Training/Certification Programs

Contractor worker training on airless spray equipment operation. Course includes use of a paint simulator, exam, materials, equipment, and a hands-on application assessment.

Airless Spray Basics (C12)

Training/Certification ProgramsBridge Maintenance: Conducting Coating Assessments

This course covers the fundamental inspections skills required to conduct a visual coating condition assessment of an in-service steel bridge. It provides a wide range of concerns that can affect the condition of the coating and presents a reporting and rating system that coincides with the AASHTOWare BrM coating rating system, enabling the owner to make an educated decision on how to repair the damaged and deteriorated coating.

Training/Certification Programs

Inspecting Containment

This course reviews how an inspector checks that the surface preparation and debris collection methods employed match the containment requirements and minimize or prevent emissions from escaping the work area. It also reviews how the inspector verifies the amount of emissions escaping from a containment area.

Training/Certification Programs

The Protective Coatings Specialist (PCS) is a professional certification that identifies individuals mastery in knowledge, principles and practices of industrial protective coatings technology.

Protective Coatings Specialist(PCS)

Training/Certification Programs

Protective Coatings Inspector certification provides training in methods of inspection for protective coatings and linings. BCI Level 2 meets ASTM D3276 “Standard Guide for Painting Inspectors”

Bridge Coatings Inspector (BCI)

• By being aware of industry standards, training and certifications you can properly specify a coating system for a specific environment and structure to ensure a quality project

Summary