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

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 Visual surface cleanliness Removal of all visible grease, oil & debris Verify correct type Visual & conductivity and cleanliness of meter abrasive media 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 (complex) Inspection Item Technique/ Instrumen t Frequency of Tests Standard Test Method Reference Spec. Referenc e 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 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 Visual Prior to surface preparation NA 3.4.1 Properly installed & maintained

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 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 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 Coating thickness Ambient conditions Recoat window/free of contamination Performed for each coating applied

Hold Point 6 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 Instrument/Guide Name Guides 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

Developing an Inspection Plan Example based on maintenance painting of a bridge structure First, populate from the specification: Column Column Column Column 1: 3: 5: 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/ Instrumen t Frequency of Tests 100% of surfaces, prior to surface prep. Standard Test Method Reference Spec. Referenc e 45-2.03 Acceptance Criteria 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 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 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 each coat 45-2.05 Primer: 3-5 mils

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 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

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 / Instrumen t 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 demobilizati on 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/ 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 contaminatio n Verify surface chloride removal Latex patch/sleev e Clstrip/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); Conductivit y 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 1000 µS/cm 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 Verify surface profile depth Visual comparator Depth micro. Replica tape Three tests per area cleaned, per shift ASTM D 4417 Verify surface prep.-toprimer interval Visual After final surface prep., per area Verify dust removal Visual/ tactile Verify correct coating mat’ls. Visual Spec. Referenc e 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 Prior to surface prep. NA 45-2.05 OZ/EP/PU from 1 manufacturer Methods A, B, or C

Inspection Plan for Maintenance Painting of a Bridge Structure Inspection Item Technique/ Instrument Frequenc y of Tests Standard Test Method Reference Spec. Referenc e Acceptance Criteria Measure ambient conditions & surface temp. Sling psychromete r; psychrometri c 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 Light Meter Prior to SSPC Guide 45-2.07 Surf. prep &

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 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 Visual After appl. NA 45-2.08 No runs, drips,

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 enclosure integrity Visual Daily NA 45-2.09 No damage to work, property or persons Verify proper stenciling Visual Prior to demobilizati on 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 purpose and importance of an inspection plan Explained the benefits of an inspection plan Reviewed the SSPC Guide for Planning Coatings Inspection Described two basic formats of inspection plans Identified common inspection check points invoked by a specification Listed common instruments, guides and methods used to inspect Described how to extract the acceptance criteria invoked by a specification for each of the inspection check points Prepared an inspection plan for recoating a bridge

Preparing a Coating Inspection Plan THE END