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