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 doesnt 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, cont.
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/Instrumen
t

Acceptance
Criteria

Verify pre-blast
Visual
surface cleanliness

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 S/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 S/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 g/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 g/cm2

Verify
correct
abrasive
type &
cleanliness

Each lot

45-2.04

Expendable;
angular; no
oil;
<1000
Mho/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 g/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 g/cm2

Verify
correct
abrasive
type &
cleanliness

Each lot

45-2.04

Expendable;
angular; no
oil;
<1000 S/cm

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
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
matls.

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
Interm: 5-7
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:
40-100F
RH: <85%
ST +5F 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

Prior to

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/
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 g/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 S/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

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

45-2.04

1.5-3 mils

Verify
surface
prep.-toprimer
interval

Visual

After final
surface
prep., per
area

NA

45-2.04

Within same
day as blast
cleaning

Verify dust
removal

Visual/tactil
e

Prior to
primer appl.

NA

45-2.04

No visible dust

Verify correct
coating
matls.

Visual

Prior to
surface
prep.

NA

45-2.05

OZ/EP/PU from
1
manufacturer

Coating
Thickness

Calib. dry
film

After each
coat

SSPC-PA 2

45-2.05

Primer: 3-5
mils

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:
40-100F
RH: <85%
ST +5F 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

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/tactil
e

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
workmanshi

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/
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