Preparing a Coating Inspection Plan

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

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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)

8. 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

9. 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.)

10. Inspection Plan Format (simple)

11. Inspection Plan Format (complex)

12. 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

13. Hold Point 1Pre-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

14. Hold Point 2Post-Surface Preparation • Examples of inspection check points • Ambient conditions • Surface preparation media • Removal of surface contamination • Surface cleanliness • Surface profile • Surface imperfections • Waste management

15. Hold Point 3Surface Conditions for Coatings Application • Examples of inspection check points • Surface cleanliness • Ambient conditions • Recoat windows • Performed for each coating applied

16. Hold Point 4Coating 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

17. Hold Point 5Post-Coating Application • Examples of inspection check points • Coating thickness • Ambient conditions • Recoat window/free of contamination • Performed for each coating applied

18. Hold Point 6Post-Curing of Coating • Examples of inspection check points • Coating application defects (each coat) • Dry film thickness (each coat) • Pinhole/holiday detection (buried/immersion service)

19. Hold Point 7Final Inspection • Examples of inspection check points • Repair and touch-up • Waste removal • Site restoration • Verification of corrective action implementation

20. Guide to Inspection Instrumentation and Visual Guides

21. 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)

22. Inspection Plan for Maintenance Painting of a Bridge Structure

23. Inspection Plan for Maintenance Painting of a Bridge Structure

24. Inspection Plan for Maintenance Painting of a Bridge Structure

25. Inspection Plan for Maintenance Painting of a Bridge Structure

26. Inspection Plan for Maintenance Painting of a Bridge Structure

27. Inspection Plan for Maintenance Painting of a Bridge Structure

28. Inspection Plan for Maintenance Painting of a Bridge Structure

29. Inspection Plan for Maintenance Painting of a Bridge Structure

30. Inspection Plan for Maintenance Painting of a Bridge Structure

31. 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

32. Inspection Plan for Maintenance Painting of a Bridge Structure

33. Inspection Plan for Maintenance Painting of a Bridge Structure

34. Inspection Plan for Maintenance Painting of a Bridge Structure

35. Inspection Plan for Maintenance Painting of a Bridge Structure

36. Inspection Plan for Maintenance Painting of a Bridge Structure

37. 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

38. Preparing a Coating Inspection Plan THE END