21.1 Scope

21.2 Field Painting Inspection

21.3 Insulation Inspection

21.4 References

FORMS (Typical Examples Attached)
RB-26N01 Inspection and Test Record for Painting
RB-26N02 Inspection Record for Insulation

21.1 Scope

The purpose of this section is to provide guidelines to Company personnel, in particular to the Construction Specialists, for the inspection and testing of painting and insulation works.

Primary responsibility for quality is that of the subcontractor who shall satisfy himself through his own quality system that specified requirements are met.

It is the responsibility of the Construction Specialists to ensure that the subcontractor is in fact effectively applying his quality system and obtaining acceptable results.

Depending on the particular projects, the presence of, or visits from, a specialist from the paint manufacturer may be required. This service could be in the subcontractor's scope or alternatively could be directly controlled by Company

Both painting and insulation may take place not only on site but in offsite locations such as prefabrication shops under control of the Company site team.

It is important that the quality systems put into place for painting and insulation adequately cover the activities both onsite and offsite. Responsibility for their day-to-day supervision is that of the Construction Specialist supported by auditing by the Quality Assurance Manager.

Subsequent sections 21.2 to 21.3 are in effect checklists of points and recommendations requiring surveillance, inspection or testing. They are intended as a reminder and a help to the Construction Specialist. However, they are no substitute for reading and familiarizing oneself with the subcontract, requisitions, specifications, standards and drawings. In case of conflict it is these project specific document which prevail.

The subcontractor creates his own quality system, which includes proposing the inspection and testing record forms to be used. Their suitability shall be judged by the Quality Assurance Manager in consultation with the Construction Specialist (see Reference 21.4.1).

The set of inspection and test record forms attached to this section:

  • May be used as a basis to review the subcontractor's forms.
  • May be imposed on the subcontractor, should the latter's forms be considered to be unsuitable.

21.2 Field Painting Inspection

21.2.1 Introduction

An analysis of the reasons for premature coating failure - deterioration of a coating system resulting in rusting, pitting or other deterioration - in most cases leads to finding either improper surface preparation or deficient coating application.

The Function of the Construction Specialist

The Construction Specialist's purpose is to ensure that the requirements of the coating specification are met. He enforces the specification without exception. The authorization to deviate from the specification is the responsibility of the Engineering Department via the Site Engineer. The Construction Specialist certainly may venture his opinion and give recommendations to the engineer, but cannot unilaterally deviate from the specifications at the working level.

Besides specification enforcement, the Construction Specialist provides a job documentation including a commentary on the type and adequacy of equipment such as blast equipment, paint spraying equipment, compressors, etc. at the jobsite. Information regarding ambient conditions and controls, and verification that the surface preparation, coating application, coating thickness and curing are as required. Reports shall contain positive statements and not a simple yes or no as a result of the findings. This is supplemented with any other information he deems of consequence to the quality and progress of the work.

The amount and type of inspection will vary according to the size of the project and the type of application contract.

Special attention shall be given as to a) "fixed price" contractor trying to cutting corners and b) "cost-plus" contractor's approach to quality of the work.

21.2.2 Inspection

  1. In coating operations, competent inspections can yield big dividends. Adequate inspection averts production losses and improves materials performance and operational efficiency. The three most critical periods for inspection on coating application work are:
  2. The quality of surface preparation is critical, particularly when immersion conditions require a white metal blast.
  3. When coating materials are sprayed, particularly when work starts, so that standards of work expected from the spray gun operator are clearly established.
  4. When final tests on coating films are conducted, and when repair of holidays is made.

21.2.3 Recording Data

As work progresses, the inspector shall record application data and comment daily. These records can serve as valuable future references.

The Construction Specialist shall have test instruments available and in good working order.

Prior to start of painting, it is necessary to determine proper cure time on a coating material. Following are some tests used to determine cures:

  1. A coin is used to strike the surface of in-organic zinc-rich primers. If no zinc metal is removed from the surface, cure is adequate to topcoat.
  2. Most coating systems attain a definite hardness when cure is complete. To determine cure, prepare a standard with the coating system on a 150 x 300 x 3 mm mild steel panel to specified thickness. Cure for the specified time and temperature. Test the hardness of the system with a portable hardness tester (Rockwell C or other). Obtain the average hardness from 10 readings until maximum hardness is indicated. The average hardness can be used as an index number to determine when final cure of the film is reached.
  3. A quick test for cure is to briskly rub the coating with a clean, white cloth dampened with applicable solvent. If the coating is not softened and does not rub off, the cure is complete.

Instruments

Instruments shall include a pocket knife, wet film paint thickness gauge, dry film thickness gauge, high and low voltage holiday detectors (portable), magnifying glass with light source and a portable vapor-proof spotlight, instrument to evaluate blasting profile, hardness tester, instr. for relative humidity. With these it is possible to perform nearly all the initially required tests.

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