Inspection of Lining Application in Steel and Concrete Equipment – NACE SP0288
Inspection is an integral part of the lining application process. The purpose of inspection is to verify compliance to the lining application specifications and work procedures, not to question the integrity of the lining applicator. Many lining applicators perform their own inspection or hire an independent inspection agency. The NACE International Coating Inspector Training and Certification Program provides exposure to knowledge and skills pertaining to inspection of lining application.
Preparation of Protective Coating Specifications for Atmospheric Service – NACE 80200/SSPC-TR 4
General Specification Characteristics
Scope of Work
Reference Section
Definition Section
Submittals Section
Quality Assurance Section
Pre-Job Visit and Conference
Delivery, Storage, Handling, and Disposal Section
Site Conditions Section
Resolution of Conflicts
Product Specification
This portion of the specification defines the requirements for protective coating products to be employed in the work.
Project Execution
The execution section details surface preparation and application of protective coatings.
Inspection
Owner inspection requirements are normally defined in this section.
Guide for the Identification and Use of Industrial Coating Materials in Computerized Product Databases – SSPC-Guide 13
Product Data Sheet
Data Segments – Section 3
Introduction: Seven data segments represent categories of information that are necessary for the identification of an industrial coating and for recording its product data. They are:
Product description
Intended use
Physical properties
Mixing and application
Key performance parameters
Safety data
Supplemental information
Inspection of Lining Application in Steel and Concrete Equipment – NACE SP0288
Standards
Reference Section: The reference section lists all documents to be used in conjunction with the specification. No reference is made to standards or technical specifications that are not part of the specification requirements. Generally, only one standard method is referenced for each requirement, although alternative methods are often available. These documents might include, but are not limited to, those of AISC1, ASTM2, AWS3, AWWA4, ISO5, SSPC, NACE, ACI6, ICRI7, PDCA8, and coating manufacturers’ materials safety data sheets (MSDS) and product data sheets.
1 American Institute of Steel Construction (AISC), 1 E Wacker Drive, Suite 3100, Chicago, IL 60601-2001.
2 American Society for Testing and Materials (ATSM), 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.
3 American Welding Society Inc. (AWS), 550 N W Le Jeune Road, Miami, FL 33126.
4 American Water Works Association (AWWA), 6666 W Quincy Avenue, Denver, CO 80235.
5 International Organization for Standardization (ISO), Case Postale 56, Geneva CH-1211, Switzerland.
6 American Concrete Institute (ACI), P.O. Box 9094, Farmington Hills, MI 48333.
7 International Concrete Repair Institute (ICRI), 1323 Shepard Drive, Suite D, Sterling, VA 21064.
8 Painting and Decorating Contractors of America (PDCA), 3913 Old Lee Highway, Suite 33B, Fairfax, VA 22030.
SSPC Guide for Planning Coatings Inspection
Developing an Inspection and Test Plan
Scope of Inspection Plan. Prior to the start of project work, the contractor prepares, for the owner’s approval, a work plan that covers all phases of the work and completely and accurately describes all of the individual processes that make up each work phase. This plan converts the project specification requirements into a practical document for field use. The inspector must prepare an inspection plan to supplement the contractor’s work plan.
Plan Schedule. The inspection plan should include a project schedule for all phases of the work to match the schedule of the contractor’s work plan, so that the inspector is ready in advance without causing any delays in work production. The inspection plan systematically lists the inspection hold points, test methods, and acceptance criteria for each procedure in each phase of the project work.
Plan Format. There is no standard format for an inspection plan, since plans may vary significantly with different types of work to be done. A chart containing the following three columns is usually adequate for most projects:
Inspection Check or Hold Points. Identification of inspection check points for each phase of work (e.g., surface preparation, coating application, curing).
Inspection Method. Industry standards, instrumentation, and/or specific test methods or procedures required by specification.
Acceptance Criteria. Project specification requirements that must be met.
Review and Approval of Inspection and Test Plan. Coating projects often require project-specific inspection plans to be submitted to the owner for review and acceptance before the start of a project. If the contract does not require submission of an inspection and test plan, the inspector should still prepare one. An organized inspection plan, even for the smallest job, will help to assure a more efficient and comprehensive inspection with limited delays or items overlooked.
Process Control Procedures (PCPs)
Process control procedures are project-specific documents prepared by the contractor and approved by the owner (if a contract requirement) before work begins. They may be used in place of or to supplement the contractor’s work plan. They typically contain:
Contract data and the project specification
Process descriptions and required equipment
Inspection and test plan
Actions/authorization for addressing non-conformities
Requirements for worker safety, environmental control, and waste management
The inspector must be familiar with these procedures and utilize the relevant information in them to work efficiently.
Items Required for Inspection Plan Implementation
Required Documents
The inspector should become familiar with the surface preparation and coating or lining application requirements, inspection and test methods required, and the characteristics of the material being applied. Before the start of project work, the inspector should assemble and completely understand these documents:
The project specification (including all amendments and pertinent appendices)
Standards referenced in project specification (SSPC, NACE, ASTM, etc.)
Manufacturer’s product data sheets for each material used at the job site (e.g., coatings, thinner, abrasives, repair materials)
Other appropriate coating or lining procedures from the manufacturer
Test methods and inspection equipment required by the specification
Material Safety Data Sheets (MSDSs) for each product
Applicable building codes
The project specification lists all published test methods or procedures to be used. While it may permit the inspector to choose between different options, in all cases, it does list the test requirements. The standard test methods and procedures are usually consensus documents of the American Society for Testing and Materials (ASTM), SSPC: The Society for Protective Coatings, or other technical societies.
Equipment Required for Inspection
The required test methods describe the necessary instruments and procedures for performing these tests. Depending upon the materials being applied and type of structure or equipment to be coated, the specification requirements and the instrument requirements may vary from one coating project to another. The most frequently used coating inspection equipment and instruments are:
Telescoping Mirror (Multiple sizes)
Pictorial surface preparation standards (e.g, SSPC-VIS 1, 3, 4, or 5)
Replica tape and spring micrometer
Surface profile comparator
Psychrometer with psychrometric charts or tables
Air and surface thermometers
Hypodermic needle gage for determining air/abrasive pressure at the nozzle
Equipment for soluble salt extraction and analysis
Film thickness gages calibrated by the manufacturer and shims or standard plates for verifying gage accuracy
P.I.G. gage
Flashlight and mirror
Light meter
Holiday detector
These instruments should be kept clean and operational with instrument serial numbers and dates of last factory calibration noted as required. For example, serial numbers and calibration verification of DFT gages should be noted in the daily inspection documentation. The inspector should also carry spare batteries, bulbs, thermometers, and other expendable items so that work is not delayed due to inspection equipment malfunctions.
Inspection of Lining Application in Steel and Concrete Equipment – NACE SP0288
Prejob Conference – Section 2
A prejob conference shall be arranged by the owner and shall be attended by representatives of the owner, lining applicator, and the inspector.
The parties shall review the specification, procedures, latest lining material manufacturer’s data sheets, and inspection standards, and shall define details of the lining application, review safety practices, and resolve any ambiguities or conflicts.
All actions that are taken and agreed upon at the prejob conference shall be documented.
The following items shall be reviewed at the prejob conference:
Acceptable levels and methods or procedures for determining moisture content, alkalinity, and cure time required for concrete surfaces for the lining being applied
Acceptable methods for repairing concrete defects such as laitance, bug holes, rock pockets, fins, and structural cracks, and acceptable methods for treating construction and expansion joints
Acceptable methods for the removal of curing membranes and release agents
Degree of surface preparation required for welds, attachments, and surface imperfections, including those illustrated in NACE SP01786 (see Section 4)
Degree of surface cleanliness and depth of surface profile specified, and the agreed-upon standard(s) to be used for the verification of these factors
Acceptable methods of removing dust and abrasive and the test procedure for verifying degree of surface cleanliness
Lining material designation(s), including the number of coats to be applied, and method of lining application
Method of inspection for discontinuities and, if other than a holiday-free lining application is required, the number of allowable holidays or discontinuities and acceptable marking materials for highlighting discontinuities
Acceptable lining repair procedures as supplied by the lining material manufacturer
The nominal, minimum, and maximum dry film thickness (DFT) to be obtained for each coat, the final cured lining DFT, and the agreed-upon instrument to be used to measure the DFT
Number and frequency of DFT measurements to be taken
Procedure for verifying the degree of cure of the lining
Requirements for proper ventilation of solvent fumes and drying time between coats
Work sequence and scheduling, including estimated interim and final completion dates
Inspection points in the project beyond which work shall not progress until inspection has been completed and the work has been accepted
Responsible contact personnel of all parties
The extent of documentation, job control records, and number and distribution of copies required of the inspector
Inspection instrument calibration procedures
The use of destructive inspection instruments
Inspection Equipment – Section 3
Inspection equipment commonly used by the inspector for inspecting lining application includes the following:
Psychrometer (sling or automatic fan type)
National Weather Service(3) relative humidity-psychrometric tables
Surface thermometer
Hypodermic needle abrasive blasting air pressure gauge
Surface cleanliness standards (written specifications, visual comparators, and/or panels)
Weld preparation standard and replica
Surface profile replica tape or comparator
pH paper
Wet film gauge
DFT gauge (nondestructive) and calibration standards
DFT gauge (destructive), (e.g., Tooke gauge)
Holiday detector (low- or high-voltage)
Magnifying glass (10X)
Moisture meter
Inspection equipment shall be calibrated before, during, and after use when applicable. The frequency of calibration shall be as specified in the lining application specification.
Inspection equipment that is destructive or detrimental to the integrity of an applied lining shall not be used for routine inspection. If a destructive test is necessary to verify degree of surface preparation, number of coats applied, adhesion, or total OFT achieved, the damaged area resulting from the test shall be repaired in accordance with procedures agreed upon during the prejob conference and as specified in the lining application specification.
SSPC Guide for Planning Coatings Inspection
Documentation of Findings
Inspection data are often recorded in the inspector’s logbook as they are taken and then transferred onto inspection forms. The documentation must include all inspection findings, especially non-conformities, in a clear, concise, and timely manner, so that findings are easily understood and not confusing, lost, or forgotten. If a problem arises, this information can be a key component to its resolution, especially in avoiding litigation. Copies of the documentation are periodically forwarded to responsible contractor and owner quality assurance personnel. The owner personnel review these documents to gain assurance that both the original work and any corrective actions are in conformance with specification requirements. Thus, the inspector serves both the owner and the contractor project quality management systems.
Log Book
Daily Report
Weekly or periodic Report
Instrument Calibration
Discrepancy Report
Photographic