Specifying For Inspection

 
By: Malcolm McNeil

When writing a coating specification, often the writer may want to specify the level of competency for the coating inspector who will be doing the day-by-day inspection of the surface preparation and coating application involved in the project.   To do this, the specification writer must first complete the section in the spec that details the inspection process that is to be used during the project.  The inspection section of the spec should include all tests that are to be performed and the instruments that are to be used to perform the tests.  Pass/fail criteria should be spelled out in this section.

Once the inspection section of the specification is complete, the spec writer will have the information necessary to make the proper decision as to what level inspector will be required to perform the inspection procedures on a particular project. But what exactly do those levels mean?

NACE International defines the qualifications for the Level 1, Level 2, and Level 3 Coating Inspector as follows:

Level 1 – Upon successful completion of Coating Inspector Program (CIP) Level 1 the inspector should be able to:
•    Undertake simple coating inspection work on
      structural  steel, on site, under direct  supervision of
     a qualified (Level   3) inspector
•    Read and understand a coating specification for
     surface   preparation and coatings application
•    Use inspection equipment for basic quality control, including but not limited to:
-    Sling psychrometer and weather tables (psychrometric charts)
-    Wet-film thickness (WFT) gauge
-    Magnetic pull-off dry film thickness (DFT) gauges
-    Electromagnetic DFT gauges
-    Low-voltage (wet-sponge) holiday detector
-    High-voltage DC holiday detector

•  Understand and use surface preparation standards
   (NACE, SSPC, and ISO)  to recognize specified surface cleanliness
•    Recognize the inspector’s job as part of a team effort
•    Recognize the importance of pre-job meetings
•    Recognize the need to determine the inspector’s responsibilities
      and authority
•  Recognize the value of record keeping, and learn what information to record and how to fill out inspection reports
Level 2 – Upon successful completion of CIP Level 2 the inspector should be able to perform all those tasks listed for CIP Level 1 and:
•  Undertake coating inspection work in a fixed coatings facility (shop)                                       
•  Use destructive coating inspection equipment, including: paint inspection gauges (Tooke gauges), adhesion testers, impressor hardness testers, pencil hardness testers
•    Use eddy current electronic gauges for DFT measurements on nonferrous surfaces
•    Test for soluble chemical salt contamination (including ferrous and chloride ions)
•    Recognize coating techniques used in specialized circumstances, including pipeline coatings, sheet linings, brick and tile linings, etc.
•    Recognize the personality types present in most work environments and some techniques that can be used to reduce friction and improve working relationships
•    Recognize the techniques and some of the problems associated with coating concrete
•    Recognize some specialized coating techniques, including: spray metalizing, hot-dip galvanizing, automated coatings application, including dip, roller, flood, and coil coating
•    Understand the role of product technical data sheets and material safety data sheets. (MSDS) in communication of coatings information
•    Understand various generic types of coatings, including fireproofing, anti-foulings, high-heat coatings, and temporary protectives
•    Recognize common coating failure modes  
•    Recognize some laboratory testing methods used to establish coating performance criteria as well as evaluate coating failures
•    Recognize the role of cathodic protection in corrosion prevention, particularly when used with coatings

Level 3 – To attain NACE Certified Coating Inspector Level 3 the inspector should be able to perform all those tasks listed for Level 1 and Level 2 and must have two years field experience before taking, and passing, the Peer Review exam.  The Peer Review exam is a two-hour-long oral exam, consisting of six technical questions and four practical questions.  Level 3 Coating Inspectors have proven their technical knowledge and ability to communicate regarding practical issues that may arise on site.  They are capable of supervising coating inspection technicians.  Peer Review examinations are conducted by contemporaries of the coating inspection industry and experts in their field of work.
Using these guidelines the spec writer can select which level of independent NACE-Certified coating inspector he or she should specify for the project being considered.  By specifying a NACE-Certified, third party coating inspector, the spec writer can have confidence that the work will be done in compliance with the specifications, or that work which does not comply will be identified and the proper repairs can then be performed.

If the specification is properly written, the small cost of utilizing the services of a NACE-Certified coating inspector is recouped many times over by insuring that the work will be done in compliance with the specifications, resulting in a quality, long lasting coatings job.

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