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Inspection Plan
William D. Corbett
KTA-Tator, Inc.
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
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
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
Benefits of a Coatings
Inspection Plan
Coating specifications can be complex
documents
Specifications typically contain the quality
requirements for a coatings project
Good inspection doesnt 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
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
SSPC Guide for Planning
Coating Inspection, cont.
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)
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
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.)
Inspection Plan Format
(simple)
Inspection Item Technique/Instrument Acceptance Criteria
Psychrometric charts Determining relative humidity (%) and dew point temperature
Latex patch/sleeve & chloride indicator strips/tubes Extracting and analyzing surface chloride concentrations
Replica tape and spring micrometer Measurement of surface profile (ASTM D4417, method C)
Blotter paper Assessing compressed air cleanliness
SSPC VIS 1 Assessing surface cleanliness after dry abrasive blast cleaning
Dry film thickness gage Measuring the applied dry thickness of paint
Low voltage pinhole detector Locating pinholes and holidays (misses) in coating systems
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)
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify grease/ 100% of 45-2.03 No visible oil or
oil removal surfaces, grease
prior to contamination
surface prep.
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify grease/ 100% of 45-2.03 No visible oil or
oil removal surfaces, grease
prior to contamination
surface prep.
Verify surface Three tests 45-2.03 < 7 g/cm2
chloride per 1000 sq.
removal ft.
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify grease/ 100% of 45-2.03 No visible oil or
oil removal surfaces, grease
prior to contamination
surface prep.
Verify surface Three tests 45-2.03 < 7 g/cm2
chloride per 1000 sq.
removal ft.
Verify correct Each lot 45-2.04 Expendable;
abrasive type angular; no oil;
& cleanliness <1000 Mho/cm
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify grease/ 100% of 45-2.03 No visible oil or
oil removal surfaces, grease
prior to contamination
surface prep.
Verify surface Three tests 45-2.03 < 7 g/cm2
chloride per 1000 sq.
removal ft.
Verify correct Each lot 45-2.04 Expendable;
abrasive type Angular
Verify Once per 45-2.04 No visible oil or
compressed shift water on
air cleanliness collector
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify grease/ 100% of 45-2.03 No visible oil or
oil removal surfaces, grease
prior to contamination
surface prep.
Verify surface Three tests 45-2.03 < 7 g/cm2
chloride per 1000 sq.
removal ft.
Verify correct Each lot 45-2.04 Expendable;
abrasive type angular; no oil;
& cleanliness <1000 S/cm
Verify Once per 45-2.04 No visible oil or
compressed shift water on
air cleanliness collector
Verify post- 100% of 45-2.04 SSPC-SP 10
blast surface surfaces,
cleanliness prior to
primer appl.
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Verify surface Three tests 45-2.04 1.5-3 mils
profile depth per area
cleaned, per
shift
Verify surface After final 45-2.04 Within same day
prep.-to-primer surface prep., as blast cleaning
interval per area
Verify dust Prior to 45-2.04 No visible dust
removal primer appl.
Verify correct Prior to 45-2.05 OZ/EP/PU from 1
coating matls. surface prep. manufacturer
Coating After each 45-2.05 Primer: 3-5 mils
thickness coat Interm: 5-7 mils
Finish: 2-3 mils
Verify finish Prior to finish 45-2.05 Fed. Std. 151B
coat color coat appl. No. 23456
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Spec. Acceptance
Item Instrument of Tests Test Method Reference Criteria
Reference
Measure Prior to 45-2.06 Air & Surf. Temp:
ambient coating 40-100F
conditions & mixing and 4 RH: <85%
surface temp. hr. intervals ST +5F of DP
Verify proper During mixing 45-2.07 Mechanical
mixing of mixing blade
coatings
Verify straining Prior to trsfr. 45-2.07 Strained
of primer to spray pot
Verify proper Prior to 45-2.07 Type & amount
thinning addition per manuf. PDS
Verify lighting Prior to 45-2.07 Surf. prep & ctg
production appl: Min 20 fc
Verify lighting Prior to 45-2.07 Minimum 50 fc
inspection
Inspection Plan for Maintenance
Painting of a Bridge Structure
Inspection Technique/ Frequency Standard Test Spec. Acceptance
Item Instrument of Tests Method Reference Criteria
Reference
Verify spray During primer 45-2.07 Constant
pot agitation application agitation during
appl. Stirrer w/i
2 from bottom
Verify primer Prior to primer 45-2.08 Spray
appl. by spray appl.
THE END