recognize the need for coating inspectors to be effective communicators
outline how to efficentively participate in the prejob conference
min attended by contractor, owner or owner’s rep and inspectors
2. should have an agenda, sign in sheet and some who is not the inspector record the minutes
describe the importance of quality record keeping throughout a coating projects
- inspection documentation acts as a quality control tool.
- For inspector is important from a legal standpoint.
- At organization level, good inspection documentation can guide future projects to develop future effective maintenance program.
CIP level1 should be reviewed by
supervisors before they submit to owner/user
7 C’s
- Completeness - contain all the required infomration
- Clarity - clear easily understandable
- Courtesty - Cnsider the feelings and viewpoints of the reciever
- Conciseness - precise , logical, relevant and to the point
- Correctness - use proper grammer and accurate information
- Consistency - Use a consistent tone, voice
- Concreteness - be factual and leave no room for misinterpretation
Before the project
1.clarify the responsibilities, authorities , deliverables
2. clarify any abiguities, omissions or conflicts found within guidance
During the project
coordinate with team member to perform inspection task
inform stake holders of any issues of non conformities
after the project
document all inspection task
complete and submit the specified reports
type of communications (4)
- verbal - through speech
- written - written symbols
- non-verbal - without words (body language)
- visual - graphical representations
Type of documentations (8)
- logbooks - informal tool use to record field measurement and observation
- daily reports - detail the problem encounter, inspection tasks performed and the results achieved
- Weekly Report - provide high level, progress
- RFI - uses to gather additional information to determine what step to take next - to clarify information gaps
- NCR - outline deviation from the requirement of the specification and record teh resolution
- CAR - verify that any NC has been resolve or accepted as is by owner
- Material inventory Reports - track the inventory or stock of materials on site
- other reports - such as instrument calibration , project documentations records (track acknowledge receipt of project documents, change orders, , test results)
daily reports includes (7)
- environmental conditions
- location of work inspected that day
- deviation or NC
- explanation of any work stoppages
- Estimate of % of work completed
- Results of inspection and standards and specification applied
- photo video or test results
Describe the 5 environmental conditions that are monitored
- Surface temp - measure of the temp of the surface being coated. Min is usually 40F and max is 125 F. Affect solvent evaporation, curing rates, and improper film formation
- Air temp - at night steel radiates heat , at day absorbs heat , higher air temp can result in shorter pot life, shorter induction time and lower viscosity, lower cure time . low air temp = adhesive issues, longer pot life, longer induction time and higher viscosity.
- Relative humidity - impacted by air temp , amount of water vapor : max amount of water vapor the air can hold at that temp. high RH affect curing , should stay BELOW 85% to prevent moisture from forming and 40% to prevent corrosion, lead to solvent entrapment
- Dew Point - 5 below surface temp , function of air temp and RH
- Wind speed - cause overspray and dry spray (when solvent evaporates before the paint stream reaches the substrate)
RH vs dew point
RH = a measure of the amount of water vapor in the air compared
dew point = temperature at which atmospheric air becomes saturated with water
surface preparation takes place in 3 phases
3 phases
1. initial surface condition assessment - visually assessing the surface to determine: type of substrate, initial condition ,design challenges and fabrication defects that would affect the surface preparation or coating process.
2. precleaning the surface -removal of visible and non visible surface contaiments.
Visibal = dirt, grimes, oil
Non visual = salts, chlroides, sulfates and nitrates
3. surface prepartion
Describe the role of the initial condition assessment in preparing a surface for coating application
- identify type of substrate
- Determining the condition of the substrate
- Identify substrate challenges and defects
- identify type of substrate because type of metal affects the choice of surface preparation
“most common substrates are steels
1. new or unpainted steels - removal of mill scales, blast cleaning using either shot or grit
2. previously coated steel surfaces - coated surface should be checked prior to surface preparation to identify the coating condition, type of coating, and recommendation for removal or overcoat. damage coating should be removed, intact coating , clean with solvent , dully and smooth hard glossy coating through abrasion and feather edge
3. SS - remove any film to prevent the coating from detaching from substrate (may only require degreasing or water rising)
4. Galvanized steel - remove loosely adhered film/ oxides or powdery zinc salts by water washing, light blast cleaning, treating with an acid solutions (ASTM D6386 - std practice of preparation of Zinc)
5. Aluminum - check for oxidations, remove oil and grease, if corroded , wire brush or light blasting (ASTM D1730)”
- Determining the condition of the substrate
determine as it will impact the appearance of the surface after it has been prepared. Use SSPC visual guides
visual guides for surface cleanliness of CS is ____applicable to SS . VIS guides are ____to the written NACE/SSPC standards
NOT / supplemental
visual guides (4) - VIS and (1) ISO
SSPC-VIS3 - power and hand tool cleaning
SSPC- VIS 1 - dry abrasive blast cleaning
SSPV VIS 4/NACE 7 - waterjetting
SSPC VIS5/NAC 9 - wet abrasive blast cleaning
ISO 8501 -1 - combines both hand/power tool cleaning and abrasive blasting in the same standards
VIS and ISO A-D grades
VIS guide A-D grades “A-100% mill
B - rust and mill
C - 100% rust
D- rust and pitting”
- Identify substrate challenges and defects “surface defects = (5)
(1) laminations - imperfection in steel that is created during the folling process, results from blister, seams , scratches . Remove by gridning or scraping and cehcked before and after surface prep.
(2). Inclusions - non metallic impurties that are trapped in the metal at continuous - remove by chipping and or gridning , weld filling can then restore the surface
fabrication defects=
(3) Gouges - share indentation caused by mechancial damages - Round indentation with a file or grinder so the entire surface can be evenly
(4). shapre angles bend corners - create surface tension , result in a thinner DFT-round all sharp bends/corners to a smooth radius. Stripe coat prior to coating application
(5) imperfect welds , rough /skip/weld splatter = grind the weld smooths / gap filled with asealer or caulking / remove with impact tool or chipping hammer or grind down.
design challenges
1. threads
2. dissimilar metals
3. gaps/crevices
4. angles and corners
5. overlaping surfaces “
surface prep purpose (3)
“1 remove contaminants that could result in premature coating failures
2. attain a specfied level of cleanliess
3. rougen the surface to create the required profile good coating adhesions”
premature failures are often the results of
inadequate surface prepartion
surface prepartion is the process of (2)
cleaning and roughening a substrate before a coating is applied
