Inspection Planning Keys to Successful In process QAQC

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

Webinar Content Ø Planning to perform inspection of coating operations Ø Comprehending project documents Ø Gathering referenced standards Ø Verifying correct type and functionality of inspection instruments Ø Verifying safety training and site-compatible PPE Ø Understanding documentation procedures & formats Ø Developing an Inspection Plan Ø Purpose and benefits Ø Common formats Ø Preparation

Learning Outcomes • Completion of this webinar will enable the participant to: Ø Describe the value and importance of thorough planning to perform inspection of coating operations Ø Describe the purpose, benefits and common formats of a written Inspection Plan Ø Prepare an inspection plan

INSPECT PREPARE PLAN

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? Ø Get clarification on entries • Who needs to sign them (besides you)? • Distribution?

Prepare an Inspection Plan • What is an Inspection Plan? Ø A road map for QA and QC inspection personnel Ø Lists what to inspect, how to inspect and what is acceptable according to the project specification Ø Prevents missed inspection check points/hold points Ø 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 • Documents ØProject specification ØReferenced standards (SSPC, NACE, ASTM, etc. ) ØProduct data sheets ØSDS • Inspection Equipment and Guides ØThe 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) Ø Inspection Check Point Ø Method of Inspection Ø Acceptance Criteria • Complex ØSimple 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

Inspection Plan Format (complex) Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria

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

Hold Point 1 Pre-Project & Pre-Surface Preparation • Examples of inspection check points ØContractor submittals ØSurface preparation media ØCoatings materials ØContainment and ventilation ØWaste management ØSurface contamination ØOil, grease and debris ØSoluble salts

Hold Point 2 Post-Surface Preparation • Examples of inspection check points ØAmbient conditions ØSurface preparation media ØRemoval of surface contamination ØSurface cleanliness ØSurface profile ØSurface imperfections ØWaste management

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

Hold Point 4 Coating Application • Examples of inspection check points ØCoatings materials ØMixing, thinning and straining ØAmbient conditions ØWet film thickness ØCoatings application defects • Performed for each coating applied

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

Hold Point 6 Final Inspection • Examples of inspection check points ØRepair and touch-up ØWaste removal ØSite restoration ØVerification 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: Column 3: Column 5: Column 6: Inspection check point column Frequency of test column Specification reference column 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 Verify grease/ oil removal Technique/ Instrument Frequency of Tests 100% of surfaces, prior to surface prep. Standard Test Method Reference Spec. Reference 45 -2. 03 Acceptance Criteria No visible oil or grease contamination

Inspection Plan for Maintenance Painting of a Bridge Structure Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference 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/cm 2

Inspection Plan for Maintenance Painting of a Bridge Structure Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference 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/cm 2 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/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference 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/cm 2 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/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference 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/cm 2 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 postblast 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. Reference Acceptance Criteria Verify surface profile depth Three tests per area cleaned, per shift 45 -2. 04 1. 5 -3 mils Verify surface prep. -toprimer 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 mils Interm: 5 -7 mils Finish: 2 -3 mils Verify finish coat color Prior to finish coat appl. 45 -2. 05 Fed. Std. 151 B No. 23456

Inspection Plan for Maintenance Painting of a Bridge Structure Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Measure ambient conditions & surface temp. Prior to coating mixing and 4 hr. intervals 45 -2. 06 Air & Surf. Temp: 40 -100°F RH: <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/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference 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. Reference 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. 04 45 -2. 05 Daylight hours only

Inspection Plan for Maintenance Painting of a Bridge Structure • Complete the inspection plan by populating the remaining two columns ØInspection instrument/technique ØStandard test method reference

Inspection Plan for Maintenance Painting of a Bridge Structure Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference Verify grease/ oil removal Visual and/or water break Verify surface chloride removal 100% of surfaces, prior to surface prep. SSPC-SP 1 45 -2. 03 No visible oil or grease contamination Latex patch/sleeve Cl- strip/tube Three tests per 1000 sq. ft. SSPC Guide 15 45 -2. 03 < 7 µg/cm 2 Verify correct abrasive type & cleanliness Visual; Vial test (oil); Conductivity meter Each lot SSPC AB 1; Oil: ASTM D 7237 Conductivity: ASTM D 4940 45 -2. 04 Expendable; angular; no oil; Verify compressed air cleanliness Blotter test Once per shift ASTM D 4285 45 -2. 04 No visible oil or water on collector Verify postblast surface cleanliness SSPC VIS 1 100% of surfaces, prior to primer appl. 45 -2. 04 Near-white Blast SSPC-SP 10 Acceptance Criteria <1000 µS/cm

Inspection Plan for Maintenance Painting of a Bridge Structure Inspection Item Technique/ Instrument Verify surface profile depth Depth micrometer or replica tape Verify surface prep. -toprimer interval Frequency of Tests Standard Test Method Reference Spec. Reference Acceptance Criteria Three tests per area cleaned, per shift ASTM D 4417; SSPC-PA 17 45 -2. 04 1. 5 -3 mils 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 D 7091; SSPC-PA 2 45 -2. 05 Primer: 3 -5 mils Interm: 5 -7 mils Finish: 2 -3 mils Verify finish coat color Visual (check label) Prior to finish coat appl. NA 45 -2. 05 Fed. Std. 151 B No. 23456

Inspection Plan for Maintenance Painting of a Bridge Structure Inspection Item Technique/ Instrument Frequency of Tests Standard Test Method Reference Spec. Reference 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°F RH: <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. Reference 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. Reference 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. 04 45 -2. 05 Daylight hours only

Summary • During this webinar, we have: Ø Described the importance of thorough planning to perform inspection of coating operations Ø Described the purpose, benefits and common formats of an Inspection Plan ØPrepared an inspection plan based on a simulated bridge coating project

Inspection Planning Keys to Successful In -process QA/QC Inspection During Coating Operations Questions