William D. Corbett KTA-Tator, Inc.

1. Inspection PlanningKeys to Successful In-process QA/QC Inspection During Coating Operations William D. Corbett KTA-Tator, Inc.

2. 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

3. 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

4. INSPECT PREPARE PLAN

5. 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

6. 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

7. 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

8. 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

9. 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?

10. Prepare an Inspection Plan • What is an Inspection Plan? • A road map for QA and QC inspection personnel • Lists 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

11. 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

12. 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

13. Required Items for Developing an Inspection Plan • Documents • Project specification • Referenced standards (SSPC, NACE, ASTM, etc.) • Product data sheets • SDS • Inspection Equipment and Guides • The project specification and referenced standards will identify the appropriate test methods and equipment required

14. 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.)

15. Inspection Plan Format (simple)

16. Inspection Plan Format (complex)

17. Common Inspection Hold Points • Pre-surface preparation • Post-surface preparation • Surface conditions for coatings application • Coating application • Post-coating application • Final inspection

18. Hold Point 1Pre-Project & 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

19. 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

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

21. 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

22. Hold Point 5Post-Coating Application • Examples of inspection check points • Dry film thickness (each coat) • Recoat window/free of contamination (each coat) • Coating application defects (each coat) • Pinhole / holiday detection (buried/ immersion service)

23. Hold Point 6Final Inspection • Examples of inspection check points • Repair and touch-up • Waste removal • Site restoration • Verification of corrective action implementation

24. 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)

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

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 • Complete the inspection plan by populating the remaining two columns • Inspection instrument/technique • Standard test method reference

35. Inspection Plan for Maintenance Painting of a Bridge Structure

36. Inspection Plan for Maintenance Painting of a Bridge Structure

37. Inspection Plan for Maintenance Painting of a Bridge Structure

38. Inspection Plan for Maintenance Painting of a Bridge Structure

39. Inspection Plan for Maintenance Painting of a Bridge Structure

40. 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

41. Inspection PlanningKeys to Successful In-process QA/QC Inspection During Coating Operations Questions