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 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 < µg/cm2 Verify correct abrasive type & cleanliness Each lot 45-2.04 Expendable; angular; no oil; [...]... 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... 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... 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... 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... 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... 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... 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. . .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... Reference Acceptance Criteria Verify surface profile depth Three tests per area cleaned, per shift 45-2.04 1.5-3 mils Verify surface prep.-toprimer 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... 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 ... 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... 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 Pre-Surface Preparation • Examples of inspection check points Contractor submittals Surface preparation media Coatings materials Containment and ventilation Waste