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-14

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
How Do I Test for Soluble Salt Contamination?..............................................................................3-17
How Do I Test for Specific Ions and Conductivity?.........................................................................3-17
Selecting a Field Sampling and Testing Method..............................................................................3-18
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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)............................................3-20
Surface Sampling Method C: Latex Cell (Bresle PatchTM and BresleSampler®)............................3-20

Methods of Sample Testing

Converting Between Surface Conductivity and Surface Concentration...........................................3-21

Analyzing Surface Extactions for the Sulfate Ion.............................................................................3-24
Measuring Ambient Conditions........................................................................................................3-23
Using Electronic Psychrometers to Measure Ambient Conditions...................................................3-24
Using Surface Temperature Measuring Instruments.........................................................................3-26
Calibrating Instruments for Measuring Ambient Conditions and Surface Temperature..................3-27
Documenting Ambient Conditions and Surface Temperature..........................................................3-27
Dehumidification...............................................................................................................................3-28
Assessing Lighting and Surface Cleanliness....................................................................................3-31
Methods of Surface Preparation........................................................................................................3-33
Selecting a Visual Standard..............................................................................................................3-39
Using SSPC-VIS 3, “Guide and Reference Photographs for Steel Surfaces Prepared by
Power and Hand Tool Cleaning”................................................................................................3-41
Using SSPC-VIS 1, “Guide and Reference Photographs for Steel Surfaces Prepared by
Dry Abrasive Blast Cleaning”....................................................................................................3-59
Using SSPC-VIS 5/NACE VIS 9, “Guide and Reference Photographs for Steel Surfaces
Prepared by Wet Abrasive Blast Cleaning”................................................................................3-68
Conducting a Compressed Air Cleanliness (Blotter) Test................................................................3-76
Abrasives...........................................................................................................................................3-78
Abrasive Cleanliness.........................................................................................................................3-82
Measuring Surface Profile Depth......................................................................................................3-83
Using the Surface Profile Comparator..............................................................................................3-85
Using the Surface Profile Depth Gage..............................................................................................3-85
Using Replica Tape .........................................................................................................................3-85
Calibrating Surface Profile Measuring Instruments..........................................................................3-86
Documenting Surface Profile Measurements ...................................................................................3-87
Using Portable Stylus Instruments for Determining Peak Density...................................................3-87
Waterjetting.......................................................................................................................................3-89
SSPC/NACE Joint Surface Preparation Standards Waterjetting of Metals......................................3-90

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 Using SSPC-VIS 4 /NACE VIS 7, “Guide and Reference Photographs for Steel Surfaces
Prepared by Waterjetting”...........................................................................................................3-92
Chemical Stripping...........................................................................................................................3-99
Inspection of Surfaces for Primer Application................................................................................3-100
Summary.........................................................................................................................................3-102

Instrument Use Supplement...............................................................................................3-137

Using Psychrometers to Measure Ambient Conditions......................................................................1-2

Using Electronic Psychrometers to Assess Ambient Conditions and Surface Temperature...............1-8
Using Surface Temperature Measuring Instruments.........................................................................1-17
Calibrating Instruments for Measuring Ambient Conditions and Surface Temperature..................1-19
Documenting Ambient Conditions and Surface Temperature..........................................................1-20
Using the Keane-Tator Surface Profile Comparator...........................................................................2-2
Using Digital Surface Profile Gages...................................................................................................2-5
Using Replica Tape...........................................................................................................................2-10
Calibrating Surface Profile Measuring Instruments..........................................................................2-14
Documenting Surface Profile Measurements....................................................................................2-15
How to Test for Soluble Salt Contamination......................................................................................4-2
How to Test for Specific Ions and Conductivity.................................................................................4-3
Selecting a Field Sampling and Testing Method................................................................................4-4
Collecting a Sample............................................................................................................................4-6
Surface Sampling Method B.............................................................................................................4-10
Surface Samping Method C..............................................................................................................4-12
Testing the Collected Samples..........................................................................................................4-18
Sample Testing Method 5: Conductivity..........................................................................................4-31
Combination Extraction and Analysis..............................................................................................4-35

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
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 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
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........................................................................................................5-44
Measuring the Thickness of Individual Layers Using Destructive Means.......................................5-51
Documentation Procedures Relating to Inspection of Dry Film Thickness.....................................5-53
Assessing Intercoat Cleanliness........................................................................................................5-54
Detecting Amine Exudate (Blush) on Polyamide and Polyamide-Cured Surfaces..........................5-54
Documentation Procedures Relating to Verification of Intercoat Cleanliness and
Conformance to Recoat Intervals...............................................................................................5-55
Assessing Coating Cure....................................................................................................................5-55
Assessing Coating Film Hardness....................................................................................................5-57
Measuring Adhesion.........................................................................................................................5-60
Detecting Pinholes and Holidays .....................................................................................................5-63

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 Verifying the Accuracy of High Voltage Holiday Detectors.............................................................5-65
Inspecting Fluorescent Coating Systems..........................................................................................5-66
Summary...........................................................................................................................................5-68

Instrument Use
Supplement...............................................................................................5-101

Calculating Target Wet Film Thickness..............................................................................................5-2

Measuring Wet Film Thickness..........................................................................................................5-5
Adjusting and Using the Elcometer®456 wht PINIP™ Probe.........................................................6-23
Adjusting and Using the Fischer Dualscope® MPOR.....................................................................6-27
What is a Tooke Gage?.......................................................................................................................8-1
Measuring Adhesion by the Knife Test (ASTM D6677)..................................................................9-11
Measuring Pull-Off Adhesion (ASTM D4541; ASTM D7234).......................................................9-13
Measuring Adhesion Using the Elcometer® Model 106..................................................................9-15
Measuring Adhesion Using the HATE® Adhesion Tester................................................................9-22
Measuring Adhesion Using the PATTI® Quantum Series Analog Adhesion Tester........................9-28
Measuring Adhesion Using the PosiTest® AT Adhesion Tester.......................................................9-38
Special Requirements for Tensile Adhesion Testing of Coatings on Concrete.................................9-45
Tensile Adhesion Testing: Record the Type and Location of Break.................................................9-47
What are Pinholes and Holidays?.....................................................................................................10-1
Selecting a Holiday Detector............................................................................................................10-2
Using a Low-Voltage (Wet Sponge) Holiday Detector.....................................................................10-3
Using a High-Voltage (Spark) Holiday Detector..............................................................................10-6
Verifying the Accuracy of High-Voltage Holiday Detectors..........................................................10-11

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

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 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

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

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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

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

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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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