inspection planning keys to successful in-process qa/qc inspection during coating operations william...
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Inspection Planning
Keys to Successful In-process QA/QC Inspection During
Coating Operations
William D. Corbett
KTA-Tator, Inc.
Webinar Content Planning to perform inspection of coating operations
Comprehending project documents Gathering referenced standards Verifying correct type and functionality of inspection
instruments Verifying safety training and site-compatible PPE Understanding documentation procedures & formats
Developing an Inspection Plan Purpose and benefits Common formats Preparation
Learning Outcomes
• Completion of this webinar will enable the participant to:
Describe the value and importance of thorough planning to perform inspection of coating operations
Describe the purpose, benefits and common formats of a written Inspection Plan
Prepare an inspection plan
PLAN
INSPECT
PREPARE
Comprehend Project Documents
• Obtain a copy of the coating specification (the key document!)
• Obtain copies of manufacturer’s product data sheets
• Read & comprehend all• Watch for discrepancies• Prepare a list of
questions
Gather Referenced Standards
• Review “referenced standards” section of the specification
• Obtain copies of industry standards (watch version)
• E.g., ASTM, NACE, SSPC, etc.
• Read and comprehend• Standards change over
time
Verify Correct Type and Functionality of Inspection Instruments
• Review specification for required instruments & visual guides
• Compatibility of probes• Operation• Currency of calibration• Verification of accuracy• Battery status• Expendables
Verify Safety Training and Site-Compatible PPE
• Currency of general safety training
• Site-specific safety training
• Medical surveillance• Site-specific PPE• PPE compatible with
site conditions
Understand Documentation Procedures & Formats
• Many types of forms
• Electronic or handwritten?
• Some forms are designed to auto-populate directly from the inspection gage
• Your forms?
• Someone else’s forms?Get clarification on entries
• Who needs to sign them (besides you)?
• Distribution?
Prepare an Inspection Plan
• What is an Inspection Plan?A road map for QA and QC
inspection personnelLists what to inspect, how to
inspect and what is acceptable according to the project specification
Prevents missed inspection check points/hold points
Enables QA and QC personnel to focus on inspection requirements in a project specification
Purpose of an Inspection Plan
• A systematic inspection and testing plan that covers all phases of work in sequence
• A tool enabling QA/QC inspectors to navigate through and extract inspection check points from the specification
• May be a required contract submittal
Benefits of a Coatings Inspection Plan
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
Provides a key communication tool between QA and QC inspection personnel
Required Items for Developing an Inspection Plan
• DocumentsProject specificationReferenced standards (SSPC, NACE, ASTM, etc.)Product data sheetsSDS
• 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
Inspection Plan Format (simple)
Inspection Item
Technique/Instrumen
t
Frequency of Tests
Standard Test
Method Reference
Spec.Referenc
e
Acceptance Criteria
Inspection Plan Format (complex)
Common Inspection Hold Points
• Pre-surface preparation• Post-surface preparation• Surface conditions for
coatings application• Coating application• Post-coating application• Final inspection
Hold Point 1Pre-Project & Pre-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 pointsAmbient 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
• Performed for each coating applied
Hold Point 5Post-Coating Application
• Examples of inspection check pointsDry film thickness (each
coat)Recoat window/free of
contamination (each coat)Coating application
defects (each coat)Pinhole / holiday
detection (buried/ immersion service)
Hold Point 6Final Inspection
• Examples of inspection check pointsRepair and touch-
upWaste removalSite restorationVerification of
corrective action implementation
Let’s Develop 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 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 Plan for Maintenance Painting of a
Bridge StructureInspection
ItemTechnique/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 cleanliness
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 Plan for Maintenance Painting of a Bridge Structure
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 Plan for Maintenance Painting of a Bridge Structure
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 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/
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
Inspection Plan for Maintenance Painting of a Bridge Structure
• Complete the inspection plan by populating the remaining two columnsInspection instrument/techniqueStandard 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 contamination
Verify surface chloride removal
Latex patch/sleeveCl- strip/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);Conductivity meter
Each lot SSPC AB 1; Oil: ASTM D 7237Conductivity:ASTM D 4940
45-2.04 Expendable; angular; no oil;
<1000 µS/cm
Verify compressed air cleanliness
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 Plan for Maintenance Painting of a Bridge Structure
Inspection Item
Technique/Instrument
Frequency of Tests
Standard Test
Method Reference
Spec.Referenc
e
Acceptance Criteria
Verify surface profile depth
Depth micrometer orreplica tape
Three tests per area cleaned, per shift
ASTM D 4417;SSPC-PA 17
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 Prior to primer appl.
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
ASTM D7091;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 Plan for Maintenance Painting of a Bridge Structure
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 Plan for Maintenance Painting of a Bridge Structure
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
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 of a Bridge Structure
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 importance of thorough planning to perform inspection of coating operations
Described the purpose, benefits and common formats of an Inspection Plan
Prepared an inspection plan based on a simulated bridge coating project
Inspection Planning
Keys to Successful In-process QA/QC Inspection During
Coating Operations
Questions