Role

The principal role of the inspector is:

 To ensure the work is done in accordance with the specification.

 To assist in obtaining a good quality paint job
 Liaise between the parties.

The inspector is not a supervisor and should not attempt to get involved with
contractual or commercial matters.
Duties

O - Observe

Observe the works including surface preparation and coating activities.

A - Assess

Assess the quality of the works as per the contract or painting specification.

D - Document

Record and document all the works being conducted.

R - Report

Report any anomalies or coating activity issues.

Surface Preparation

Obtain advice from the paint manufacturer on the most suitable surface
preparation standard for the paint with regard to performance and
environmental requirements.

Any advice offered by the paint supplier should be confirmed in writing.

All correspondence should be maintained within the contract file.

Be aware of the local environmental bylaws and regulations.

Paint Application

Check that the application method, tip size, pressures, thinners, over-coating
times and other data as detailed in the manufacturer's product data sheets are
being complied with.

Product data sheets should be available on site for all the materials to be used
during the contract.

Be aware of any specific or special application criteria relating to paint or

coating application.
Liaison

All parties have to be familiar with the specification and agree on the surface
preparation and paint application requirements.

To do this liaison is necessary between the parties and building a good

working relationship with good communication channels is essential.

The coating Inspector should be fair and reasonable and not ask for things
that are not contained in the contract or coating specification.
The Parties

The parties involved in a contract can vary, for example:

Shipbuilding

Shipyard, Ship Owner, Contractor, Classification Society and Paint

Manufacturer.

Bridges or Construction

Highways Agency, Local Authority, Architect, Civil Engineer, Contractor, Paint

Manufacturer.

The contract or coating specification should define the duties of the coating
inspector.
Inspector Qualities

The following qualities are required:

 Experience.
 Inspector Qualifications.
 Maturity.
 Diplomacy.
 Firmness.
 Have good technical Ability.
 Level Headed.
 Good communication Skills.

The Inspector is not a coating consultant and should be aware of their roles
and responsibilities on a particular contract.
Inspector Knowledge

The inspector should have knowledge of the following:

 Location problems (shop, site).

 Methods of surface preparation and cleaning.
 Paint characteristics.
 Application methods.
 Principles of corrosion.
 National regulations, standards, codes.
 Design problems.
 Paint technology.
 Cathodic protection.
 Galvanizing.
 Metal sprayed coatings.
 Protection of welds.
 Degradation of coatings.
 HS&E risk factors.
 Methods of waste disposal.
Inspector Knowledge

Location problems (shop, site)

The inspector should have a knowledge of surface treatments conducted both

with in-house facilities and site facilities. Knowledge of the possible difficulties
working within these environments is expected of the inspector.

Paint shop facilities can vary tremendously between contracts. The Inspector
can never assume all paint shop facilities are in excellent working order and a
continuous investment program is in place.
Inspector Knowledge

Methods of surface preparation and cleaning:

The inspector is expected to have a thorough understanding of the types of

surface preparation and cleaning methods available. Also be aware of the
requirements for surface treatments for specific coatings and environments.

A good knowledge of specific Standards used on a job is essential.

Inspector Knowledge

Paint characteristics:

The inspector should have a broad knowledge of paint coatings and the
characteristics of the main generic coating types including epoxies,
polyurethanes, silicates and silicone, polyesters, vinyl esters and alkyd.
Knowledge of specialist coatings such as powders, rubber, tapes etc should
also be known.

The Inspector should gain knowledge on any new products that are
introduced into the market.
Inspector Knowledge

Application methods:

The inspector should be familiar with the various types of application methods
including brush, roller, airless spray, air-assisted spray and specialist methods
of application. The advantages and disadvantages of each method should also
be understood.

The product data sheets or application data sheets generally advise on the
correct type of application equipment. The Inspector should ensure the
correct application equipment is used.
Inspector Knowledge

Principles of corrosion:

The inspector should understand the basic principles of corrosion and how the
process can be controlled by the use of protective coatings etc.

The inspector should also understand the different forms of corrosion

including galvanic, pitting, erosion, crevice etc and the different types of
metallic materials used.
Inspector Knowledge

National regulations, standards, codes of practice:

A number of International Standards, regulations and codes of practice are

used in the coatings industry.

The inspector should be familiar with the main documents commonly

specified specifically visual preparation standards for preparation, cleanliness
and coating application and methods of corrosion control with protective
coatings.
Inspector Knowledge

Design problems:

The inspector should be aware of the potential design problems that occur in
corrosion control.

The inspector should also be familiar with specific standards and codes of
practice relating to design.
Inspector Knowledge

Paint technology:

The inspector should have a good technical knowledge of paint technology

including the basic ingredients, manufacture, and characteristics of the various
types of coatings and binders.

A knowledge of basic formulation and contents such as the binder, pigment,

solvents should be familiar to the inspector.
Inspector Knowledge

Cathodic protection:

Cathodic protection can be used with and without the use of coatings. The
inspector should be familiar with the corrosion process, the different types of
cathodic protection and use of specific coatings.

Also the areas of use for cathodic protection and the potential problems
relating to under and over protection.
Inspector Knowledge

Galvanizing:

Galvanizing as a method of corrosion control is an effective and popular

process. The inspector should have a sound knowledge of the galvanizing
process, specifically steelwork protected by hot-dip galvanizing and
subsequent over painting.

The inspector should have knowledge of galvanizing cleaning and pre-

treatments for painting.
Inspector Knowledge

Metal sprayed coatings:

Thermal metal spray is a long and established method of corrosion control,

specifically with the use of aluminium and zinc.

The inspector should have a good knowledge of thermal coatings and the
requirements for a high level of surface preparation. Knowledge of specific
standards relating to preparation and coating application is expected.
Inspector Knowledge

Protection of welds:

Virtually every steel structure has some form of welding, which if not treated
and protected properly will lead to potential corrosion and coating failure. The
inspector should be familiar with the treatment of welds, both pre-
preparation, and post-preparation.

Also the need for additional treatment during coating operations

Inspector Knowledge

Degradation of coatings:

Coatings will wear out in time. Knowledge of coatings will allow the asset
owner the correct time to do maintenance or refurbishment. The inspector
should possess this knowledge on the degradation of the various types of
coatings that are used in specific environments
Inspector Knowledge

Health, Safety and Environmental Risk factors:

With every aspect of work and more specifically surface treatments, there are
Health, Safety and Environmental risks, both to personnel and the
environment.

The inspector should be familiar with the risks associated with the work and
the risk assessments available.

Knowledge of general legislation should also be known by the inspector.

Inspector Knowledge

Methods of waste disposal:

Waste disposal varies from country to country. The type and level of disposal
can often vary from contract to contract.

The inspector should be aware of the local waste disposal requirements and
legislation. Also be aware of the types of waste that will be produced during
surface treatments including abrasives, solvents, and paints.
Inspector Skills

The inspector should have the following skills and be able to:

 Read and understand specifications

 Read and understand drawings
 Plan and carry out work to specification
 Calibrate and use inspection equipment
 Use tables and standards
 Confirm reference areas
 Prepare and distribute reports

The inspector should also be able to understand trade terminology and

industry expressions
Inspector Skills

The inspector should be knowledgeable about:

 Surface preparation
 Proper use of paint systems
 Compatibility of paint
 Design factors such as dissimilar metals
 Assembly and production methods
 Classification of environments
 Surface conditions
 Locations
 Workmanship
 Deviations from specifications
 HS&E protection
 Colour and shades
 Application
 Documentation and reports
Attitude and Behaviour

Developing a confrontational relationship should be avoided as this would

inevitably lead to advice and suggestions being ignored.

Being fair, constructive with technically sound suggestions lead to a good

working relationship.

Alcohol and drug abuse will not be tolerated and it should be noted that
outside of working hours restaurants, bars, nightclubs etc can also be
frequented by staff from the other parties.
Duties

The duties include:

 Ensure surface preparation standards are achieved.

 Ensure paint application is carried out in accordance with the
specification.
 Monitor the environmental conditions.
 Keep accurate records
Observation and Assessment

To do this the inspector should be knowledgeable of:

 Specification
 Procedures
 Paint Data Sheets
 Drawings
 Progress Plans
 General execution of the works and correct methodology for conducting
preparation and coating operations
Surface Preparation

Surface preparation can be divided into three stages:

 Steel pre-treatment
 Primary surface preparation
 Secondary surface preparation.

The inspector's duties in respect of the above are to identify defects and
ensure that they are corrected in line with the specification or contract.
Paint Application

The major inspection requirements are:

 Measurement of wet film thickness.

 Measurement of dry film thickness (after each coat in a multi-coat
system).
 Examination to ensure stripe coats have been adequately applied.
 Final inspection (after water testing in the case of tank coatings).
Environmental Conditions

Measurement of air temperature, steel temperature, and relative humidity are

carried out regularly at the job location to ensure that the environmental
conditions are within the specification for surface preparation, paint
application, drying and curing.

It is often necessary to take the measurements more than once per day if for
example work is continuous or conditions are prone to rapid change.
Records

Daily Log:

This is the major part of the recording system and contains details of:

Environmental conditions, rust grade and cleanliness degree, abrasive,

roughness, type and batch No. of paint, DFT per coat and total DFT,
start/finish times, and area reference.

More than one daily log form may be required if work is being carried out in
more than one area of the project at the same time.
Records

Tank Coating Log:

It is often convenient to record all aspects of the internal coating of one tank
on a dedicated form rather than have to trace the records back through
numerous daily logs.
Records

Progress Reports:

These are often required by head office on a weekly basis to provide concise
information concerning the job progress. They are in effect a summary and
could include information on defects and corrective actions or difficulties
encountered.
Records

Non-Conformity Reports:

These are issued in the event that defects identified during inspections are not
rectified as requested. They contain sections for technical explanations and for
cancellation if the defect is subsequently rectified.
Records

Technical Reports:

If a fault becomes apparent and is significant, a senior member of staff or an

external consultant is often called to investigate. The report should have the
aim of describing the problem, assessing the extent, establishing causation,
recommending corrective action and drawing a conclusion, together with
photographs.
Inspection Procedures

The procedure is the way in which the inspection is carried out and will vary
for different types of contract.

Generally the contractors QC department will inspect the stage of the work
e.g. surface preparation, have defects corrected and then call upon the
inspector to examine the work when any further defects found are corrected.

The same situation would occur for all other stages of DFT measurements of
each coat and examination of stripe coat application.
Inspection Planning

On simple projects, the inspections are controlled principally by the rate of

production of the contractor.

On more complex projects more than one inspector could be involved and
daily meetings could be required where the contractor produces a list of
inspections planned for that day to enable the inspection team to distribute
the workload.
Check Points

 Steel pre-treatment
 Primary surface preparation including de-greasing and removal of
soluble salts
 Secondary surface preparation
 1st Coat DFT
 1st Stripe Coat
 2nd Coat DFT
 2nd Stripe Coat (etc)
 Final Inspection
Reference Areas

These are often used as a basis for determining the paint manufacturers
liability should defects arise after the work has been completed.

The reference areas are prepared and coated in strict accordance with the
specification and accepted by a representative of the paint manufacturer.

They should be chosen by representatives of the owner and paint

manufacturer.

The dimensions are specified and the locations clearly defined.

Criteria for Acceptance/Non-Acceptance

The specification should be specific on the standard of surface preparation

required and refer to a published standard such as ISO 8501-1 which would be
used as the criteria.

In the case of dry film thickness, the specification would often refer to the
90/10 rule which means that 90% of the readings have to be greater than or
equal to the NDFT and that none of the remaining 10% shall be less than 0.9 x
NDFT.

Other such rules are also available.

Standards, Specifications, Procedures

The inspector should be familiar with all the standards detailed in the
specification, specific specifications and procedures to be adopted for the
works.

Procedures may include inspection test plans and method statements.

All forms of inspection procedures and activities are to be agreed in advance

of the works.
Punch List

From the results of the final inspections and from notes from previous
inspections a list is compiled that identifies defects that have to be corrected
before the area can be accepted as complete.

The inspector will generally sign-off the completed areas as requested by the
contractor.
Quality Control/Quality Assurance

Quality control is:

The routine systematic inspection and testing conducted to verify specification

conformance.

Quality Assurance is:

The verification that the quality control implemented by the contractor meets
the requirements of the specification.

The sequence of quality control and quality assurance is:

Quality control personnel inspect the work, verify correction of non-

conformities and then re-inspect the work before the quality assurance
inspection takes place.
Ethics

Definition: Motivation defined by the ideas of right and wrong.

The inspector should have a high level of personal integrity, a strong work
ethic to provide quality monitoring of a project and a fair accountability to all
parties.

The inspector should not impose personal standards but be aware that the
acceptability of work is the requirements of the specification.

The above is applicable to both quality control and quality assurance

functions.
Paperless Quality Assurance (1)

Accurate records are essential to provide assurance to the client that surface
preparation and coating application is being carried out in accordance with
the specification and inspection procedures.

In this respect, digital data management is a useful tool and has the
advantages of:-

 Reduces measurement and recording time

 Reduces inspection delays
 Keeps data up to date
 Reduces paperwork
 Reduces the time to produce a coating technical file
 Allows statistical analysis of data
 Documents can be scanned to create electronic files
Paperless Quality Assurance (2)

Common inspection tasks that can benefit from digital data management are:-

 Measurement of the surface profile

 Measurement of environmental conditions
 Measurement of dry film thickness
 Photographic records

The data can be recorded in a number of ways:-

 Transfer from the measuring equipment at the job site to a PDA for later
entry into the computer.
 Direct entry into the computer from the measuring instruments.
Paperless Quality Assurance (3)

By using digital data management, hours of time can be saved from recording
and assessing data and producing reports.

The quality documents are up to date and easily referenced.

The time can be utilised for inspection of the work and provide cost savings.
Detection of Oil on a Surface

Black Light

Significance and Use

Black light will cause many hydrocarbon oils to fluoresce.

It should be noted that some synthetic oils will not fluoresce under black light
exposure which may result in a false negative result for the presence of oil
contamination.

Scope

To detect surface oil a short or long wavelength black light is shone onto the
surface where a bright yellow/green fluorescence indicates the presence of oil
or grease contamination.

In daylight conditions, the area may need to be shaded from atmospheric

light.

Lint or fibres from the cloth on the surface may fluoresce but are not
indicative of oil contamination.
Leadership Requirements, Technical Skills and Teamwork

There may be contracts were a number of coating inspectors are used on a

single site or a number of sites.

A lead inspector (supervisor) is often used to oversee the contract inspection

personnel.

This role will encompass management and supervision skills as you will
responsible for project organisation and responsibilities of coating inspectors
who may not have the technical knowledge you have or the possible field
experience.

As with all senior roles, an understanding of management is a requirement as

subordinates have to work within a structure which is co-ordinated allowing
individuals to work with a specific independence while being part of a team
with an overall manager.
Leadership requirements, Technical Skills and Teamwork

Job responsibilities should be clearly defined where a number of coating

inspectors are on a specific project or contract.

A project organisation chart should be developed showing levels of authority.

Each role will have their responsibilities detailed and this should be discussed
at the start of the contract.

The job specification should acknowledge the qualification of the coating

Inspector to ensure the Inspector is not subject to testing or decision making
outside the training or capabilities of the individual.
Leadership Requirements, Technical Skills and Teamwork

The senior coatings inspector will be fully qualified such as NACE level 3,
ICorrLevel 3, FROSIO level 3 (red card ) and fully certificated with SSPC.

It would also be expected that the senior coatings inspector will have a
number of years field experience and technical knowledge to understand the
specification and all inspection processes and procedures. Comprehensive
knowledge of Inspection equipment and interpretation of the results is
essential.

The ability to write comprehensive technical reports is also a requirement of a

senior coatings Inspector. Presentation skills are also important when reports
need to be presented to project teams etc
Leadership Requirements, Technical Skills and Teamwork

The senior coatings Inspector should be familiar with Quality Management

Systems and the audit process.

The senior coatings inspector may have to conduct different types of audits
such as on the coatings inspectors roles and documentation or the contractor
working to the specification or inspection test plans.

Vendor assessments may have to be conducted pre-contract to ensure the

contractor is capable of conducting the works.

It is therefore essential that the senior coatings inspector is fully experienced.

Leadership Requirements, Technical Skills and Teamwork

The senior coatings Inspector should have good leadership skills and
understand there could be personal issues with his/her team inspecting
contractor's work.

The ability to gain respect from all parties is important and difficult decisions
will sometimes have to be made even though this may be reprimanding or
removing inspectors from a project.

Supporting the team is essential, however, the senior coatings Inspector

should be capable of making decisions which are overall best for the whole
team and project.
Summary

Within this training unit, we have reviewed the duties of a painting (coating)
inspector. We have discussed the importance of seeking advice from the
material suppliers, check to be conducted on the works, involvement of
different parties, the inspector's qualities, experience, knowledge, duties, and
qualifications along with leadership skills.

We also discussed Quality Assurance, Quality Control and the paperless

methods of documentation and recording.