Introduction

Introduction

I Welcome and Course Introduction

Welcome to the SSPC Protective Coatings Inspector (PCI) Training

Program. The objective of this course is to thoroughly train individuals
in the proper methods of inspecting surface preparation and installation
of industrial and marine protective coatings and lining systems to
an array of industrial structures and facilities. The course provides
participants five days of intensive training and includes multiple
workshops and problem solving exercises so that participants may
immediately apply the learning in a classroom setting, without the
pressures of production and project schedules. In order to enhance the
learning environment and illustrate the importance of teamwork, the
workshops and exercises will be done in small teams. The teams will
be formed later during this introduction module.

This course is completed with a comprehensive written examination

and a practical (instrument use) examination, which will be graded by
the instructors and SSPC staff. SSPC is an approved training provider
through the International Association for Continuing Education and
Training (IACET). Therefore, participants scoring 70% or higher
on each of the examinations (written and practical) will be eligible
to receive Continuing Education Units (CEUs) from SSPC through
IACET.

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Effective Feb. 11, 2008, the SSPC PCI program received an American
Bureau of Shipping (ABS) Certificate of Conformance stating that it
is considered to be equivalent to NACE Coating Inspector Level 2 and
FROSIO Inspector Level III when taught by instructors certified to
either of these programs with at least two years relevant experience.
This complies with IACS Procedural Requirement (PR) No. 34
Rev. 1 January 2008. Effective December 1, 2009, Lloyd’s Register,
the world’s largest commercial shipping classification society, has
approved SSPC’s Protective Coatings Inspector (PCI) program as
equivalent to NACE Coating Inspector Level 2 and FROSIO Inspector
Level III.

In addition, participants can pursue certification through SSPC

depending on industry experience and other prerequisites which will
be described later in this introduction module.

Participation Guidelines

Participants are urged to actively engage in the training by asking

questions, offering relevant observations, and learning as much as
possible about and from other members of their work teams. The
instructors will encourage you to ask for clarifications whenever you
need them. If you feel an instructor is moving over significant material
too quickly, ask them to slow the pace or repeat an important point.
You will find that, whenever possible, the instructors are willing to
help you during breaks and over lunch, even at the end of a training
day.

The Course Syllabus

The following section includes a short syllabus of the thirteen

modules, a description of the hands-on workshops and problem
solving exercises.

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An Introduction to SSPC’s Protective Coatings

Inspector Training

The introduction to SSPC’s Protective Coatings Inspector Training

is an orientation to the training, and as such, provides a backdrop for
the course, including the history of industrial coatings as a protector
of steel against corrosion and deterioration. This overview also
explores other influences on the development of new industrial
coating products. The relationship of quality control practices and
successful coating projects is another focal point. Also addressed are
the problems associated with premature coating failures, including a
perspective on causes and prevention. The introductory module ends
with the course learning outcomes, training participation guidelines,
industry acronyms, common terminology, and a syllabus of each
module. This is also the module where participants are introduced to
the instructors and to each other and where housekeeping items are
addressed.

Module One: Protecting Metal Surfaces From

Corrosion: The Role of High Performance Coatings

Module One explains how coatings protect metal surfaces from

corroding. Corrosion is a process where metals give up energy and
return to their natural state. Some metals have a stronger propensity
to corrode than others, but all metals corrode eventually. Only four
elements need to be present for corrosion to occur: an anode, a
cathode, a metallic pathway, and an electrolyte. While the corrosion
of metal surfaces cannot be completely halted, it can be slowed. The
most widely used method to prevent/slow corrosion today, particularly
on carbon steel, is the application of high performance coatings.
Module One explains how today’s high performance coatings use
barrier protection, sacrificial or cathodic protection, and inhibitive
protection to protect modern day steel structures from the inevitable
process of deterioration and decay. There is no workshop for Module
One.

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Module Two: The Roles of Quality Assurance (QA)

and Quality Control (QC) Inspectors on a Coatings
Project

Module Two compares the roles of QA and QC inspectors on coatings

projects. All too often, the lines between the QC and the QA on a
coatings project get blurred. When that happens, the scope of work
and responsibility for that work can get blurred in the process. This
module is designed to clarify the common roles and responsibilities
of both the contractor’s QC inspector and the Owner’s QA inspector.
This is a textbook: the way it would work in a perfect world, but it is
helpful to know how things “could/should” work before getting caught
up in the day to day rush of a real world coatings project. Module
Two compares and contrasts the role of the QA and QC inspector on
a typical coatings project. The commonalties are explored, including
understanding the specification, reviewing the product data sheets (the
PDS) and the material safety data sheets (the MSDS), comprehending
the industry standards relevant to the specific project, documenting
hold or checkpoints, and understanding paper trails. Module Two also
explores the critical differences in the two roles, including issues of
authority, reporting, testing, and documentation (which again, depend
on the scope of work and the specification). Another issue explored by
this module is the management of nonconformities.

Module Three: Surface Preparation

Module Three explains the inspection of surface preparation.

Preparing the surface in accordance with the specification can be the
most costly phase of a coatings operation, and it is always critical to
the project’s success. Surface preparation has a major focus in this
training program, which covers in detail common standards used
throughout the industry. The initial phase of pre-surface preparation
and the inspection hold points are covered first, detailing the problems
of weld spatter, edges, and repair areas. Surface preparation, which
follows, covers the many methods used to clean and roughen
surfaces, with a special emphasis on dry abrasive blast cleaning. The
International Organization for Standardization (ISO) and SSPC: The
Society for Protective Coatings have developed a series of consensus
standards to govern surface cleanliness requirements. This module will
explore the content of these standards including descriptions of what

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must be removed from the surface and what may remain on the surface
for each standard. In addition to the surface preparation standards,
the training will also focus on means and methods, including: blast
cleaning equipment, a variety of abrasives, wet and dry abrasive blast
cleaning, centrifugal blast cleaning, vacuum blast cleaning, hand
and power tools, and water jetting. An overview of methods used to
prepare concrete surfaces and the inspection processes involved with
the preparation of concrete are included in this module. Methods for
controlling the environment during surface preparation are described.
The final focal points for Module Three are the common inspection
checkpoints for surface preparation and the methods used to verify
adherence to the specification.

Module Three Inspection Case Study: Surface Preparation

of the Interior and Exterior of an Elevated Potable Water
Storage Tank

Participants are provided with a project description that presents

quality issues associated with surface preparation activities on an
elevated water storage tank. Participants work in teams to address the
issues from an inspector’s perspective.

Module Three Workshop A: Comprehension of SSPC

Surface Cleanliness Standards

Participants are provided with a matrix containing various components

to the written SSPC surface cleanliness standards and 14 of the 15
SSPC surface cleanliness codes. Participants complete the matrix
on their own, then compare and defend answers as a team prior to
revealing the team answers to the class using a team spokesperson.

Module Three Workshop B: Use of Instruments, Standards

and Test Kits for Surface Preparation Inspection

Participants work in teams using SSPC surface cleanliness visual

guides, instruments for measuring surface profile depth, light meters,
and kits for assessing the cleanliness of abrasive and for assessing
surface concentrations of chloride. The use of conductivity meters,
and equipment for assessing dust on prepared surfaces is also included
in the workshop. Participants transfer the workshop answers from the
worksheets to SSPC inspection documentation forms. Data generated

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during the workshop is compared to specification requirements.

Participants record whether the results of their inspections indicate
conformance to the specification.

Module Four: Practical Arithmetic for the Coatings

Inspector

Module Four reviews practical arithmetic skills used by the coatings

inspector. Coatings inspectors frequently need to apply basic
arithmetic skills to everyday inspections. This module provides a
review of common arithmetic associated with coatings inspection,
including: converting percentages to decimal format; calculating area;
calculating volume, converting from specific weight to percentage of
thinner addition; converting VOC values; converting temperatures, and
converting units of measurement for surface profile depth and paint
thickness (mils to microns and back). A special session on calculating
coating material quantities based on theoretical and practical coverage
rates is also included in this module.

Module Four Workshop:

Participants are challenged with sample problems (based on life-like

inspection scenarios) that require application of the arithmetic skills
acquired in Module 4. A calculator is required for this workshop.

Module Five: Coating Mixing, Thinning, and

Application

Module Five explains the inspection of coating mixing, thinning

and application. Experts claim that poor application, along with
inadequate surface preparation, cause the majority of all industrial
coating failures. This module will overview the various methods used
to apply coatings, including conventional (air) spray, airless spray,
HVLP, air-assisted airless spray, plural component spray and brush
& roller. The advantages and limitations of each method, along with
proper technique will be emphasized. Module Five will continue with
the inspection of mixing, thinning, and coating application processes,
including measuring ambient conditions, witnessing and documenting

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mixing and thinning procedures, wet and dry film measurements, use
of the destructive gages to determine the thickness of individual layers
in a coating system, pinhole/holiday detection, adhesion, and coating
hardness and curing tests. The unique aspects associated with coating
of concrete complete Module Five.

Module Five Inspection Case Study: Application of

Coatings to the Interior and Exterior of an Elevated Potable
Water Storage Tank

Participants are provided with a project description that presents

quality issues associated with coating application activities on an
elevated water storage tank. Participants work in teams to address the
issues from an inspector’s perspective.

Module Five Workshop A: Navigating a Coating Product

Data Sheet (PDS)

Participants are provided with a coating manufacturer’s PDS and a

list of inquiries. Teams of participants navigate through the PDS and
answer each of the inquiries. The workshop teaches where the most
useful information is on a data sheet, and enforces the importance of
the document and the importance of reviewing the document before a
project begins.

Module Five Workshop B: Use of Instruments for Coating

Application Inspection

Participants work in teams using instruments for: assessing ambient

conditions and surface temperature; calculating wet film thickness
(with and without thinner addition); measuring dry film thickness
using Type 1 and Type 2 coating thickness gages; determining
conformance to SSPC-PA2; measuring dry film thickness using
destructive gages; detecting pinholes and holidays using low voltage
holiday detectors; and measuring adhesion. Participants transfer
the workshop answers from the worksheets to SSPC inspection
documentation forms. Data generated during the workshop is
compared to specification requirements. Participants record
whether the results of their inspections indicate conformance to the
specification.

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Module Five Workshop C: Identification of Coating Film

Defects

Color photographs of various coating defects are provided. Participants

work in teams to identify the defects and their likely causes.

Module Six: Industrial Protective Coatings and

Coating Systems

Module Six introduces the basic components in an industrial coating:

non-volatiles and volatiles. Subsequently, VOC (volatile organic
compound) regulations will be explored in the context of what a
QC or QA inspector should know about monitoring and reporting
the addition of thinner to coating products and the actual quantity of
VOC emitted into the atmosphere during application. In Module Six,
participants will also learn how coatings cure. An overview of coating
types and coating characteristics will be followed by key inspection
concerns by specific coating type. Module Six includes an overview
of common coating systems used in a number of industries including:
water storage/tanks; power generation (both coal and nuclear); waste
water treatment; pulp and paper; lock and dam; chemical plants;
buried pipeline; food and beverage; ships/marine vessels and highway/
bridges. The unit concludes with an explanation of how coating
systems are evaluated for performance.

Module Seven: Specialty Inspection Projects

Module Seven describes non-routine inspection projects that can

pose special challenges to the coatings inspector. Inspecting in
the fabrication shop, powder coating applications, thermal spray
coating (metallizing) applications, and application of liquid coatings
to galvanizing (duplex system) present a different set of challenges
for a coatings inspector, as does maintenance painting in the field
when overcoating becomes the maintenance strategy. The unique
aspects of these types of inspections are described in Module Seven.
Additionally, many existing industrial structures contain coatings
with toxic metal ingredients. The hazards associated with removal,

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handling and disposal when these coatings are “disturbed” during

maintenance painting operations must be controlled. The inspector
may have responsibility for verifying proper set-up and maintenance
of containment and ventilation systems, assuring proper worker
protection, monitoring air, soil and water quality, and assuring proper
handling and disposal of hazardous waste streams.

Module Eight: Coating Failures and Methods of

Prevention

Module Eight explains how knowledgeable coatings inspectors can

help avoid coating failure. The role of the coatings inspector and the
types of inspection activities that can play a role in preventing the
failures are described. Case histories of actual coating failures are
presented to the training group. The cause, fault and repair procedures
are explored, and avoidance methods are discussed.

Module Nine: Inspector Safety

Module Nine describes basic inspector safety. Fabrication shops

and construction sites often pose significant safety concerns for a
coatings inspector. While Module nine is not designed to provide
comprehensive safety training, it makes the coatings inspector
aware of potential hazards and methods of prevention. Safety
issues described in Module Nine include fall prevention/protection,
respiratory protection, sight and hearing protection, protection from
toxic metals, and confined space entry hazards. Module Nine also
describes the purpose of site-specific environmental, safety and health
hazards planning and the inspector’s responsibility for personal safety.

Module Ten: Coatings Specifications

Module Ten explains the purpose and content of coatings

specifications. The coatings specification is the inspector’s “rule
book” for a coatings project. It describes the scope of work and the
requirements of the contract, as well as lists the inspection checkpoints
that the inspector will be responsible for. The importance of a properly

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prepared coatings specification and the general layout and components

in a specification are described in Module Ten. A sample specification
is provided, which will be used for the Module Ten workshop, and in
Modules Eleven and Twelve.

Module Ten Workshop:

The sample coating specification provided to the participants in

Module Ten is supplemented with a series of inquiries. Teams of
participants work together to navigate through the specification and
locate the answers to each of the inquiries, then note the section of the
specification where the information was found.

Module Eleven: Pre-construction Conference and

Inspection Procedure Development

Module Eleven describes the purpose and content of a pre-construction

conference and explains how to prepare an inspection plan. After
a careful review of the project specification during the Module
Ten workshop, a preconstruction conference will be conducted.
Participants are provided with an agenda of discussion items, and
Product Data and MSDS for the coatings selected for the project.
The course instructors represent the facility owner and the coating
manufacturer, while the participants represent the inspector (QA or
QC).

After the pre-construction conference is completed and actions

documented, the participants each develop an inspection procedure
based on the project specification and any outcomes of the conference.
The inspection procedure is used during the simulated coatings
inspection project (Module Twelve).

Module Twelve: Project Inspection Workshop

Module Twelve includes an inspection workshop which enables the

participants to apply learned skills from the previous eleven modules.
Inspection stations are equipped with instruments, visual guides and
miscellaneous equipment and test plates. Participants work in small

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groups to perform inspections at each station, document the results

of the inspections and compare the results to the project specification
provided in Module Ten and the inspection procedures developed in
Module Eleven. After all groups have completed all of the stations,
the participants reconvene and discuss any problems and non-
conformities observed.

Module Thirteen: International Maritime

Organization (IMO)

Module thirteen provides training to the coating inspector on the major

requirement of the IMO PSPC (Performance Standard for Protective
Coatings) MSC.215(82), “Performance Standard for Protective
Coatings for Dedicated Seawater Ballast Tanks in All Types of Ships
and Double-Side Skin Spaces of Bulk Carriers”.

SSPC Protective Coatings Inspector Training and

Certification Program

A candidate can choose one of three processes to achieve certification.

Process A – Achieving Certification After Completing the

PCI Course and Passing the PCI Course Exam

In order to qualify for the Certification Exam under Process “A,”

the candidate must successfully complete the PCI course, pass the
Course Exam, have documented a minimum of 3,000 hours of coating
inspection or related work experience, and possess 40 hours of SSPC
or approved formal coatings training.

Process B – Achieving Certification with Alternate

Inspection Training

The candidate seeking PCI Certification through Process “B” may take
the certification exam without taking the PCI training course as long
as the applicant passes the PCI Course Exam, possesses 80 hours of
formal industry training approved by SSPC, of which 40 hours must be

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formal inspection training equivalent to the body of knowledge of the

SSPC PCI inspection course.

Candidates who have already achieved NACE III Certification or

Frosio Certification can request an exemption from taking the PCI
Course Exam prior to sitting for the PCI Certification Exam.

In addition to possessing 80 hours of formal training, the candidate

must document a minimum of 3000 hours of coating inspection or
related work experience.

Process C – Achieving Certification Without Formal

Inspection Training

The process “C” candidate is eligible to take the Certification Exam by

documenting at least 7,500 hours of coating inspection or related work
experience. Even though a total of 7,500 hours of documented work
experience is required to sit for the PCI certification exam, a candidate
seeking PCI Certification under Process “C” must document at least
5,000 hours of experience before sitting for the PCI Course Exam.

Note – Examples of accepted work experience and approved training

can be found at www.sspc.org.

Passing Criteria

This course is completed with a comprehensive written examination

and a practical (instrument use) examination. Students passing both
components of the PCI Course Exam at 70% or higher can take the
written and practical certification exams. A passing grade of 80% or
higher on the written and practical certification exam is required to
become an SSPC Certified Protective Coatings Inspector.

If you fail the exam or component the second time, you must wait at
least six months before retaking the PCI training course and exams.

Anyone who is unable to pass the written course exam, the written
certification exam or the certification practical exam a third time
will be considered ineligible to participate in the PCI program for a
minimum of two years from the date of the last failed exam and will be
required to take the PCI course again to reenter the process.

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PCI Renewal

The PCI Basic Inspector level renewal term is four years from the
initial exam date. To renew at the PCI Basic Inspector Level, the
candidate must within four years take the PCI refresher course and
exam and document a minimum of 750 hours of coatings inspection
(or related) experience as it occurs during the four-year certification
period.

To renew certification for the SSPC Certified Protective Coatings

Inspector the candidate must, within four years take the PCI refresher
course and exam and document a minimum of 2,000 hours of coatings
inspection (or related) experience as it occurs during their four years
certification term.

The PCI recertification exam is available online at http://www.

sspcelearning.org.

Use of Materials and Textbooks

All manuals given to you are yours to keep and therefore to write
in. The participant workbook is written in narrative form and is
augmented with PowerPoint® slides. The agenda follows this
text from beginning to end. There’s space allotted to take notes in
the margins. You can also use highlighters to highlight significant
information. If you get lost at any point, simply ask the instructor to
refer to the workbook page number that matches the information he
or she is covering. You will also be given an agenda, which provides
a day by day outline of the training sessions. Workshops and Quizzes
are provided in a separate workbook.

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An Orientation to the Coatings Industry and Key

Organizations

As part of this introduction, we’d like to review several key

organizations that work to organize and guide the industry toward safe,
efficient, and successful coating practices:

AISC _ __________________________________________________
ANSI _ __________________________________________________
API _____________________________________________________
ASTM _ _________________________________________________
AWS ____________________________________________________
AWWA __________________________________________________
CE _____________________________________________________
CSI _____________________________________________________
EPA _____________________________________________________
ICRI ____________________________________________________
ISO _____________________________________________________
NACE ___________________________________________________
NIST ____________________________________________________
NSF _ ___________________________________________________
OSHA ___________________________________________________
SSPC _ __________________________________________________
UL _ ____________________________________________________

Common Industry Acronyms

CFM ____________________________________________________
DFT _ ___________________________________________________
IAW ____________________________________________________
MSDS ___________________________________________________
MIL _ ___________________________________________________
NCR ____________________________________________________
PDS _ ___________________________________________________
POA ____________________________________________________
PSI _____________________________________________________
QA _ ____________________________________________________
QC _ ____________________________________________________
RFI _____________________________________________________
TSC _ ___________________________________________________

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VOC ____________________________________________________
WFT_ ___________________________________________________

Other common terms:

Micrometer (Micron) _______________________________________

Mil _____________________________________________________
Mill Scale_ _______________________________________________
Hold point/checkpoint_______________________________________

Learning Outcomes

There are sixty (60) learning outcomes associated with this training
course. They are listed below. The learning outcomes pertaining
to each of the thirteen modules are repeated prior to instructing the
respective module. Successful completion of this course will enable
participants to:

1. Describe the common duties, responsibilities and the role of an

industrial coatings inspector
2. Describe the authority of a coatings inspector
3. Explain the importance of thorough documentation
4. Identify the elements of a corrosion cell
5. Describe the corrosion of metal surfaces
6. Explain how industrial coatings control corrosion
7. Describe alternative methods used to protect carbon steel from
corrosion
8. Describe the differences between quality assurance and quality
control
9. Describe the common duties of quality assurance and quality
control personnel
10. Describe the purpose and content of a pre-job or preconstruction
conference
11. Explain the purpose of an inspection procedure/plan
12. Explain the importance of inspection personnel
13. Describe the importance of proper surface preparation
14. Explain the dual objective of surface preparation
15. Define the SSPC standards for surface preparation
16. Describe common methods used to prepare surfaces for coating
17. Describe methods used to control an environment during surface
preparation activities
18. Measure and record surface profile
19. Evaluate surface cleanliness

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20. Apply practical arithmetic to coatings inspection

21. Describe the procedures associated with proper mixing, thinning,
and application of industrial coatings
22. Define the SSPC standards for coating application
23. Describe the role of the coating manufacturer on a coatings
project
24. Use MSDS and product data sheets to verify safe and proper
mixing, thinning and application of coatings
25. Describe the inspector’s role regarding coating material receipt
and storage
26. Measure and record ambient conditions and surface temperature
27. Calculate wet film thickness
28. Measure wet film thickness
29. Verify the currency of calibration and assess the accuracy of
nondestructive coating thickness gages
30. Measure coating thickness using nondestructive gages
31. Describe the SSPC standard for measurement of coating
thickness (SSPC-PA2)
32. Measure coating thickness using destructive methods
33. Detect pinholes and holidays
34. Measure coating adhesion
35. Evaluate coating cure
36. Measure coating hardness
37. Identify common coating defects
38. Describe methods used to verify intercoat cleanliness
39. Identify basic differences between house paint and industrial
protective coatings
40. List volatile and non-volatile components of a coating
41. Describe the functions of the resin, additives, pigments and
solvents in a coating
42. Describe methods by which coatings cure
43. Describe the procedures used to identify service environments
44. List advantages and limitations of various generic types of
industrial coatings
45. Describe functions of the primer, mid-coat and finish coat
46. Identify common coating systems used by various industries
47. Describe methods used to evaluate coating performance prior to
full scale installation
48. Describe the special inspection procedures associated with shop
painting, powder coatings, thermal spray coatings, and duplex
coating systems
49. Describe the unique aspects of performing coatings inspection on
an overcoating project
50. Describe the inspector’s role on projects involving disturbance of
coatings containing toxic metals
51. Describe how coatings inspection can help prevent premature
coating failure

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52. Describe the function of a coating specification

53. List the basic components of a coating specification
54. List potential safety hazards associated with coatings inspection
55. Describe the personal protective equipment used by a coatings
inspector
56. Prepare an inspection plan/procedure
57. Perform coatings inspection on industrial projects
58. Compare inspection results to specification requirements
59. Apply requirements of the IMO PSPC (Performance Standard for
Protective Coatings) MSC.215(82), “Performance Standard for
Protective Coatings for Dedicated Seawater Ballast Tanks in All
Types of Ships and Double-Side Skin Spaces of Bulk Carriers”

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