Preparing a Coating Inspection Plan William D. Corbett KTA-Tator, Inc.

Preparing a Coating Inspection Plan

William D. CorbettKTA-Tator, Inc.


• 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


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


Hold Point 5Post-Coating Application• Examples of inspection check points

Coating thicknessAmbient conditionsRecoat window/free of contamination


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 Item

Technique/Instrumen

t

Frequency of Tests

Standard Test

Method Reference

Spec.Referenc

e

Acceptance Criteria




Verify surface chloride removal

Three tests per 1000 sq. ft.

45-2.03 < 7 µg/cm2


Inspection Item

Technique/Instrumen

t

Frequency of Tests

Standard Test

Method Reference

Spec.Referenc

e

Acceptance Criteria






45-2.03 < 7 µg/cm2

Verify correct abrasive type & cleanliness

Each lot 45-2.04 Expendable; angular; no oil; <1000 µMho/cm


Inspection Item

Technique/Instrumen

t

Frequency of Tests

Standard Test

Method Reference

Spec.Referenc

e

Acceptance Criteria






45-2.03 < 7 µg/cm2

Verify correct abrasive type

Each lot 45-2.04 Expendable; Angular


Once per shift

45-2.04 No visible oil or water on collector


Inspection Item

Technique/Instrumen

t

Frequency of Tests

Standard Test

Method Reference

Spec.Referenc

e

Acceptance Criteria






45-2.03 < 7 µg/cm2


Each lot 45-2.04 Expendable; angular; no oil; <1000 µS/cm


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 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 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 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


45-2.08 Spray

Verify intercoat cleanliness

Prior to each successive coat

45-2.08 No moisture, dust, grease, etc.

Verify recoat intervals


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 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


• Complete the inspection plan by populating the remaining two columnsInspection instrument/techniqueStandard test method reference


Inspection Item

Technique/Instrumen

t

Frequency of Tests

Standard Test Method Reference

Spec.Referenc

e

Acceptance Criteria


Visual and/or water break


SSPC-SP 1 45-2.03 No visible oil or grease contamination


Latex patch/sleeveCl- strip/tube


SSPC Guide 15

45-2.03 < 7 µg/cm2


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


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 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


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 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 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


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 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


THE ENDTHE END

Preparing a Coating Inspection Plan William D. Corbett KTA-Tator, Inc.

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