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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/Instrument Acceptance Criteria

Verify pre-blast Visual Removal of all visible


surface cleanliness grease, oil & debris
Verify correct type Visual & conductivity meter Expendable, angular
and cleanliness of slag, no visible oil;
abrasive media < 1,000 S/cm
Verify compressed air Blotter test Clean, dry air; no
cleanliness evidence of water or oil

Verify installation of Visual Properly installed &


protective coverings maintained
Inspection Plan Format
(complex)
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify pre- Visual 100% of SSPC-SP 1 3.4.2 Removal of all
blast surface surface visible grease,
cleanliness oil & debris
Verify correct Visual & Each lot of SSPC AB 1 2.3.1 Expendable,
type and conductivity abrasive ASTM D 7393 angular slag, no
cleanliness of meter ASTM D 4940 visible oil;
abrasive < 1,000 S/cm
media conductivity
Verify Blotter test Twice per ASTM D 4285 3.4.7 Clean, dry air;
compressed work shift no evidence of
air cleanliness water or oil

Verify Visual Prior to NA 3.4.1 Properly


installation of surface installed &
protective preparation maintained
coverings and painting
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 Guides
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
Developing an
Inspection Plan
Example based on maintenance painting of a
bridge structure
First, populate from the specification:
Column 1: Inspection check point column
Column 3: Frequency of test column
Column 5: Specification reference column
Column 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 Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify grease/ 100% of 45-2.03 No visible oil or
oil removal surfaces, grease
prior to contamination
surface prep.
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify grease/ 100% of 45-2.03 No visible oil or
oil removal surfaces, grease
prior to contamination
surface prep.
Verify surface Three tests 45-2.03 < 7 g/cm2
chloride per 1000 sq.
removal ft.
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify grease/ 100% of 45-2.03 No visible oil or
oil removal surfaces, grease
prior to contamination
surface prep.
Verify surface Three tests 45-2.03 < 7 g/cm2
chloride per 1000 sq.
removal ft.
Verify correct Each lot 45-2.04 Expendable;
abrasive type angular; no oil;
& cleanliness <1000 Mho/cm
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify grease/ 100% of 45-2.03 No visible oil or
oil removal surfaces, grease
prior to contamination
surface prep.
Verify surface Three tests 45-2.03 < 7 g/cm2
chloride per 1000 sq.
removal ft.
Verify correct Each lot 45-2.04 Expendable;
abrasive type Angular
Verify Once per 45-2.04 No visible oil or
compressed shift water on
air cleanliness collector
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify grease/ 100% of 45-2.03 No visible oil or
oil removal surfaces, grease
prior to contamination
surface prep.
Verify surface Three tests 45-2.03 < 7 g/cm2
chloride per 1000 sq.
removal ft.
Verify correct Each lot 45-2.04 Expendable;
abrasive type angular; no oil;
& cleanliness <1000 S/cm
Verify Once per 45-2.04 No visible oil or
compressed shift water on
air cleanliness collector
Verify post- 100% of 45-2.04 SSPC-SP 10
blast surface surfaces,
cleanliness prior to
primer appl.
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify surface Three tests 45-2.04 1.5-3 mils
profile depth per area
cleaned, per
shift
Verify surface After final 45-2.04 Within same day
prep.-to-primer surface prep., as blast cleaning
interval per area
Verify dust Prior to 45-2.04 No visible dust
removal primer appl.
Verify correct Prior to 45-2.05 OZ/EP/PU from 1
coating matls. surface prep. manufacturer
Coating After each 45-2.05 Primer: 3-5 mils
thickness coat Interm: 5-7 mils
Finish: 2-3 mils
Verify finish Prior to finish 45-2.05 Fed. Std. 151B
coat color coat appl. No. 23456
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Measure Prior to 45-2.06 Air & Surf. Temp:
ambient coating 40-100F
conditions & mixing and 4 RH: <85%
surface temp. hr. intervals ST +5F of DP
Verify proper During mixing 45-2.07 Mechanical
mixing of mixing blade
coatings
Verify straining Prior to trsfr. 45-2.07 Strained
of primer to spray pot
Verify proper Prior to 45-2.07 Type & amount
thinning addition per manuf. PDS
Verify lighting Prior to 45-2.07 Surf. prep & ctg
production appl: Min 20 fc
Verify lighting Prior to 45-2.07 Minimum 50 fc
inspection
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Test Spec. Acceptance
Item Instrument of Tests Method Reference Criteria
Reference
Verify spray During primer 45-2.07 Constant
pot agitation application agitation during
appl. Stirrer w/i
2 from bottom
Verify primer Prior to primer 45-2.08 Spray
appl. by spray appl.

Verify intercoat Prior to each 45-2.08 No moisture,


cleanliness successive dust, grease, etc.
coat
Verify recoat Prior to each 45-2-08 Minimum and
intervals successive maximum per
coat PDS
Verify After appl. of 45-2.08 No runs, drips,
workmanship each coat sags or misses
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify Daily 45-2.09 No damage to
enclosure work, property or
integrity persons
Verify proper Prior to 45-3 Proper location,
stenciling demobilization size, content and
color
Verify time of Daily 45-2.04 Daylight hours
operations 45-2.05 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 Technique/ Frequency Standard Test Spec. Acceptance
Item Instrument of Tests Method Reference Criteria
Reference
Verify grease/ Visual and/or 100% of SSPC-SP 1 45-2.03 No visible oil or
oil removal water break surfaces, grease
prior to contamination
surface prep.
Verify surface Latex Three tests SSPC Guide 15 45-2.03 < 7 g/cm2
chloride patch/sleeve per 1000 sq.
removal Cl- strip/tube ft.
Verify correct Visual; Each lot SSPC AB 1; Oil: 45-2.04 Expendable;
abrasive type Vial test (oil); ASTM D 7237 angular; no oil;
& cleanliness Conductivity Conductivity:
meter ASTM D 4940 <1000 S/cm
Verify Blotter test Once per ASTM D 4285 45-2.04 No visible oil or
compressed shift water on
air cleanliness collector
Verify post- SSPC VIS 1 100% of SSPC-SP 10 45-2.04 Near-white
blast surface surfaces, Blast
cleanliness prior to
primer appl.
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify surface Visual Three tests ASTM D 4417 45-2.04 1.5-3 mils
profile depth comparator per area
Depth micro. cleaned, per Methods
Replica tape shift A, B, or C
Verify surface Visual After final NA 45-2.04 Within same day
prep.-to-primer surface prep., as blast cleaning
interval per area
Verify dust Visual/tactile Prior to NA 45-2.04 No visible dust
removal primer appl.
Verify correct Visual Prior to NA 45-2.05 OZ/EP/PU from 1
coating matls. surface prep. manufacturer
Coating Calib. dry film After each SSPC-PA 2 45-2.05 Primer: 3-5 mils
Thickness thickness coat Interm: 5-7 mils
gage Finish: 2-3 mils
Verify finish Visual (check Prior to finish NA 45-2.05 Fed. Std. 151B
coat color label) coat appl. No. 23456
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Measure Sling Prior to ASTM E 337 45-2.06 Air & Surf. Temp:
ambient psychrometer; coating 40-100F
conditions & psychrometric mixing and 4 RH: <85%
surface temp. charts; surf. hr. intervals ST +5F of DP
thermometer
Verify proper Visual During NA 45-2.07 Mechanical
mixing of mixing mixing blade
coatings
Verify straining Visual Prior to trsfr. NA 45-2.07 Strained
of primer to spray pot
Verify proper Visual Prior to NA 45-2.07 Type & amount
thinning addition per manuf. PDS
Verify lighting Light Meter Prior to SSPC Guide 12 45-2.07 Surf. prep & ctg.
production appl.: Min 20 fc
Verify lighting Light Meter Prior to SSPC Guide 12 45-2.07 Minimum 50 fc
inspection
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify spray Visual During primer NA 45-2.07 Constant
pot agitation application agitation during
appl. Stirrer w/i
2 of bottom
Verify primer Visual Prior to NA 45-2.08 Spray
appl. by spray primer appl.

Verify intercoat Visual/tactile Prior to each NA 45-2.08 No moisture,


cleanliness successive dust, grease, etc.
coat
Verify recoat Visual Prior to each NA 45-2-08 Minimum and
intervals successive maximum per
coat PDS
Verify Visual After appl. of NA 45-2.08 No runs, drips,
workmanship each coat sags or misses
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify Visual Daily NA 45-2.09 No damage to
enclosure work, property or
integrity persons
Verify proper Visual Prior to NA 45-3 Proper location,
stenciling demobilization size, content and
color
Verify time of Visual Daily NA 45-2.04 Daylight hours
operations 45-2.05 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