Table of Contents

Introduction

Welcome and Course Introduction...................................................................................................... I-1

Participation Guidelines...................................................................................................................... I-2
The Course Syllabus........................................................................................................................... I-2
An Introduction to SSPC’s Protective Coatings Inspector Training . ................................................ I-3
Module One: Protecting Metal Surfaces From Corrosion: The Role of
High Performance Coatings.......................................................................................................... I-3
Module Two: The Roles of Quality Assurance (QA) and Quality Control (QC)
Inspectors on a Coatings Project.................................................................................................. I-4
Module Three: Surface Preparation.................................................................................................... I-4
Module Four: Practical Arithmetic for the Coatings Inspector........................................................... I-6
Module Five: Coating Mixing, Thinning, and Application................................................................ I-6
Module Six: Industrial Protective Coatings and Coating Systems..................................................... I-8
Module Seven: Specialty Inspection Projects..................................................................................... I-8
Module Eight: Coating Failures and Methods of Prevention............................................................. I-9
Module Nine: Inspector Safety........................................................................................................... I-9
Module Ten: Coatings Specifications................................................................................................. I-9
Module Eleven: Pre-construction Conference and Inspection Procedure Development.................. I-10
Module Twelve: Project Inspection Workshop................................................................................. I-10
Module Thirteen: International Maritime Organization (IMO)........................................................ I-11
SSPC Protective Coatings Inspector Training and Certification Program........................................ I-11
Use of Materials and Textbooks........................................................................................................ I-13
An Orientation to the Coatings Industry and Key Organizations..................................................... I-13
Learning Outcomes........................................................................................................................... I-15

Module 1: Protecting Metal Surfaces From Corrosion: The Role of High

Performance Coatings

Corrosion Defined...............................................................................................................................1-1
The Role of Protective Coatings in Preventing/Slowing Corrosion...................................................1-2

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 The Fundamentals of Corrosion..........................................................................................................1-2
Energy Required to Convert Ores into Metals....................................................................................1-4
Dissimilar Metals................................................................................................................................1-5
Corrosion Versus Oxidation................................................................................................................1-6
What is Steel?.....................................................................................................................................1-6
Weathering Steel.................................................................................................................................1-7
How Coatings Protect the Substrate from Corrosion..........................................................................1-7
Additional Cathodic Protection...........................................................................................................1-8
Summary...........................................................................................................................................1-12

Module 2a: The Roles of QA and QC Inspection Personnel on a Coatings

Project

Quality Assurance vs. Quality Control.............................................................................................2a-1

Pre-construction (Pre-job) Conference.............................................................................................2a-7
Development of an Inspection Procedure (Plan)..............................................................................2a-9

Module 2b: Ethics (U.S. only)

Ethics.................................................................................................................................................2b-1

Module 3: Surface Preparation: Methods, Industry Standards and

Inspection

Introduction.........................................................................................................................................3-1
Module 3 Learning Outcomes............................................................................................................3-2
Overview.............................................................................................................................................3-2
The Inspector’s Role...........................................................................................................................3-3
Purpose of Surface Preparation...........................................................................................................3-3
Inspection of Surface Preparation.......................................................................................................3-3
Review of Industry Standards.............................................................................................................3-4
Pre-surface Preparation Inspection.....................................................................................................3-7
Preparation of Welds in Tanks and Vessels for Immersion Service....................................................3-8
Testing for Chemical Contamination...............................................................................................3-16

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 How Do I Test for Soluble Salt Contamination?..............................................................................3-16
How Do I Test for Specific Ions and Conductivity?.........................................................................3-17
Selecting a Field Sampling and Testing Method..............................................................................3-18

Methods of Sample Collection

Surface Sampling Method A: Surface Swabbing (Swab SCAT Kit)................................................3-20

Surface Sampling Method B: Latex Sleeve (Chlor*TestTM SCAT Kit)............................................3-24
Surface Sampling Method C: Latex Cell (Bresle PatchTM and BresleSampler®)............................3-26

Methods of Sample Testing

Sample Testing Method 1: Quantab® Chloride Titrator Strips........................................................3-32

Sample Testing Method 2: Kitagawa® Chloride Titrator Tube........................................................3-35
Sample Testing Method 3: Bresle® SCAT Kit (Drop Titration for Chloride)..................................3-39
Sample Testing Method 4: EM Quant® Iron Strip (ferrous ion)......................................................3-42
Sample Testing Method 5: Conductivity..........................................................................................3-44
Using The Horiba Conductivity Meter.............................................................................................3-45

Using Psychrometers to Measure Ambient Conditions....................................................................3-53

Using Electronic Psychrometers to Assess Ambient Conditions......................................................3-61
Using the Extech 401 Digital Psychrometer.....................................................................................3-66
Using Surface Temperature Measuring Instruments.........................................................................3-69
Calibrating Instruments for Measuring Ambient Conditions and Surface Temperature..................3-72
Documenting Ambient Conditions and Surface Temperature..........................................................3-73
Dehumidification...............................................................................................................................3-74
Methods of Surface Preparation........................................................................................................3-79
Selecting a Visual Standard..............................................................................................................3-85
Using SSPC-VIS 3, “Guide and Reference Photographs for Steel Surfaces Prepared by
Power and Hand Tool Cleaning”................................................................................................3-87
Using SSPC-VIS 1, “Guide and Reference Photographs for Steel Surfaces Prepared by
Dry Abrasive Blast Cleaning”..................................................................................................3-106
Using SSPC-VIS 5/NACE VIS 9, “Guide and Reference Photographs for Steel Surfaces
Prepared by Wet Abrasive Blast Cleaning”..............................................................................3-113
Using the Surface Profile Comparator............................................................................................3-130
Using the Surface Profile Depth Gage............................................................................................3-134

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 Using Replica Tape .......................................................................................................................3-136
Calibrating Surface Profile Measuring Instruments........................................................................3-140
Documentating Surface Profile Measurements . ............................................................................3-140
Using Portable Stylus Instruments for Determining Peak Density.................................................3-141
SSPC-VIS 12/NACE VIS No. 5, “Surface Preparation and Cleaning of Steel and Other Hard
Materials by High and Ultra-High Pressure Water Jetting Priot to Recoating:........................3-143
Using SSPC-VIS 4 /NACE VIS 7, “Guide and Reference Photographs for Steel Surfaces
Prepared by Waterjetting”.........................................................................................................3-145
Inspection of Surfaces for Primer Application................................................................................3-153
Summary.........................................................................................................................................3-156

Module 4: Practical Arithmetic for the Protective Coatings Inspector

Learning Outcome..............................................................................................................................4-1
Introduction.........................................................................................................................................4-2
Averaging a Set of Values...................................................................................................................4-2
Converting Percentages to Decimal Format.......................................................................................4-4
Calculating Area..................................................................................................................................4-5
Converting Volatile Organic Compound (VOC) Content Values.....................................................4-17
Converting Temperature...................................................................................................................4-18
Converting Units Used to Express Coating Thickness and Surface Profile Depth...........................4-19
Calculating Wet Film Thickness.......................................................................................................4-20
Calculating the Target Wet Film Thickness......................................................................................4-20
Calculating Coating Coverage Rates and Estimating Material Quantities.......................................4-26
Summary...........................................................................................................................................4-31

Module 5: Coating Mixing, Thinning and Application: Equipment Overview

and Inspection Techniques

Introduction.........................................................................................................................................5-1
Learning Outcomes.............................................................................................................................5-2
The Inspector’s Role...........................................................................................................................5-2
Review of SSPC Standards for Coating Application..........................................................................5-3
Coating Manufacturer’s Technical Data Bulletins/Product Data Sheets............................................5-4
Material Receipt Inspection and Storage Conditions........................................................................5-14

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 Inspection of Mixing, Thinning and Application of Coatings..........................................................5-16
Measuring Coating Temperature.......................................................................................................5-19
Documentation and Reporting Procedures Relating to Inspection of Coating Mixing....................5-20
Coating Mixing Procedures..............................................................................................................5-20
Coating Thinning Procedures...........................................................................................................5-24
Inspecting Thinning Procedures.......................................................................................................5-27
Documentation and Reporting Procedures Relating to Inspection of Thinning (reducing).............5-28
Coating Application Methods...........................................................................................................5-28
Spray Technique................................................................................................................................5-35
Calculating Wet Film Thickness.......................................................................................................5-37
Calculating the Target Wet Film Thickness......................................................................................5-38
Measuring Wet Film Thickness........................................................................................................5-43
Measuring Dry Film Thickness........................................................................................................5-46
Measuring the Thickness of Individual Layers Using Destructive Means.......................................5-53
Documentation Procedures Relating to Inspection of Dry Film Thickness.....................................5-60
Assessing Intercoat Cleanliness........................................................................................................5-61
Documentation Procedures Relating to Verification of Intercoat Cleanliness and
Conformance to Recoat Intervals...............................................................................................5-61
Assessing Coating Cure....................................................................................................................5-62
Assessing Coating Film Hardness....................................................................................................5-64
Measuring Adhesion.........................................................................................................................5-66
Detecting Pinholes and Holidays .....................................................................................................5-69
Using a Low Voltage (wet sponge) Holiday Detector......................................................................5-72
Using a High Voltage (spark) Holiday Detector...............................................................................5-75
Verifying the Accuracy of High Voltage Holiday Detectors.............................................................5-80
Inspecting Fluorescent Coating Systems..........................................................................................5-81
Summary...........................................................................................................................................5-84

Instrument Use Supplement

Using Magnetic Pull-off Dry Film Thickness Gages........................................................................5-94

Adjusting and Using the PosiTector®6000....................................................................................5-103
Adjusting and Using the Elcometer®456 wht PINIP™ Probe.......................................................5-111
Verifying Accuracy and Using the QuaNix® Keyless....................................................................5-116
Adjusting and Using the ElecktroPhysik eXacto FN......................................................................5-120
Adjusting and Using the Fischer Dualscope® MPOR-SK.............................................................5-126
Measuring Adhesion by the Tape Test (ASTM D3359)..................................................................5-130

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 Measuring Adhesion by the Knife Test (ASTM D6677)................................................................5-138
Measuring Pull-Off Adhesion (ASTM D4541; ASTM D7234).....................................................5-140
Measuring Adhesion Using the Elcometer® Model 106................................................................5-142
Measuring Adhesion Using the HATE® Adhesion Tester..............................................................5-149
Measuring Adhesion Using the PATTI® Quantum Series Analog Adhesion Tester......................5-155
Measuring Adhesion Using the PosiTest® AT Adhesion Tester.....................................................5-165
Special Requirements for Tensile Adhesion Testing of Coatings on Concrete...............................5-171
Tensile Adhesion Testing: Record the Type and Location of Break...............................................5-173

Module 6: Industrial and Marine Protective Coatings and Coating Systems

Introduction.........................................................................................................................................6-1
Industrial and Marine Protective Coatings Versus Paint.....................................................................6-3
Industrial/Marine Coatings: Components...........................................................................................6-3
Curing Mechanisms............................................................................................................................6-8
Identifying the Service Environment................................................................................................6-10
Characteristics by Coating/Lining Type...........................................................................................6-11
Key Inspection Concerns by Coating/Lining Type...........................................................................6-14
Coating Systems Defined..................................................................................................................6-16
Coating System Selection.................................................................................................................6-17
Performance Evaluation of Protective Coating Systems..................................................................6-28
Summary...........................................................................................................................................6-30

Module 7: Specialty Inspection Projects

Introduction.........................................................................................................................................7-1
Coatings Inspection in the Steel Fabrication Shop.............................................................................7-3
Inspection of Thermal (Metallized) Spray Coatings (TSC)................................................................7-6
Measuring the Thickness of Thermal Spray Coatings........................................................................7-8
Inspection of Powder Coatings...........................................................................................................7-9
Inspection of Galvanized Systems....................................................................................................7-11
Inspecting Overcoating Projects ......................................................................................................7-13
Inspecting on Projects Involving Removal of Toxic Metal Coatings...............................................7-18
Summary...........................................................................................................................................7-25

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Module 8: Coating Failures: Consequences and Case Studies

Introduction.........................................................................................................................................8-1
The Role of the Coatings Inspector in Failure Avoidance..................................................................8-3
The Role of the Coatings Inspector in a Failure Investigation...........................................................8-3
Case Studies of Coating Failure..........................................................................................................8-4
Summary...........................................................................................................................................8-17

Module 9: Coatings Inspector Safety

Introduction.........................................................................................................................................9-1
General Safety Responsibilities of the Coatings Inspector.................................................................9-2
Inspector Medical Surveillance...........................................................................................................9-3
Safety Monitoring...............................................................................................................................9-3
Risks....................................................................................................................................................9-4
Types of Hazards.................................................................................................................................9-5
Other Hazardous Materials Encountered by Inspectors......................................................................9-9
Hazardous Environments..................................................................................................................9-10
Personal Protective Equipment.........................................................................................................9-15
Summary...........................................................................................................................................9-18

Module 10: Navigating Coating Specifications

Introduction.......................................................................................................................................10-1
Learning Outcomes...........................................................................................................................10-1
Purpose of a Coatings Specification.................................................................................................10-2
Inspecting Against a Poorly Prepared Specification.........................................................................10-4
Inspecting When There is No Specification......................................................................................10-4
Specifying Coating Systems.............................................................................................................10-5
Components of a Coating Specification............................................................................................10-8
Summary.........................................................................................................................................10-12

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Module 11: Specification Review and Pre-Construction Conference;
Inspection Plan Development for the Inspection of a “Bottomless” Tank
Lining Installation

Introduction.......................................................................................................................................11-1
Learning Outcomes...........................................................................................................................11-1

Module 12: Simulated QA/QC Inspection of “Bottomless” Tank Lining

Installation

Introduction.......................................................................................................................................12-1
Learning Outcome............................................................................................................................12-1
Workshop Instruction........................................................................................................................12-1

Module 13: IMO Requirements

Introduction.......................................................................................................................................13-1
Learning Outcome............................................................................................................................13-2
Purpose of Standard [Paragraph 1]...................................................................................................13-2
Definitions [Paragraph 2]..................................................................................................................13-3
General Principles [Paragraph 3.1-3.333].........................................................................................13-3
Coating Technical File [Paragraph 3.4]............................................................................................13-3
Coating Standard [Paragraph 4.1-4.3]..............................................................................................13-5
Basic Coating Requirements [Paragraph 4.4]...................................................................................13-5
Coating Inspection Requirements [Paragraph 6]..............................................................................13-7

Appendix A: Comparison of SSPC and ISO Surface Preparation Standards

for Power- and Hand-Tool Cleaned Steel and Blast Cleaned Steel

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