1. Digital Data Management For Coating Inspection Tasks On Steel Structures Presented by: Joe Walker, Elcometer

2. Learning Outcomes Define digital data management
Define key sections where project information is recorded within a digital data management software package
Define surface profile, ambient conditions, and dry film thickness
Recognize how to perform profile, ambient conditions, and dry film thickness measurements

3. Introduction
Optimum corrosion protection and rigorous inspection is required – on both new build and existing structures
Protective coating maintenance costs for steel structures continue to rise
Accurate records of inspection measurements and procedures provide assurances to the owner or the purchaser that the coating is being applied properly

4. Inspection
Independent inspection provides quality assurance to the owner
The time needed to perform quality inspections will impact overall project
Inspections are necessary to meet the required standard

5. Inspection
The key therefore is to minimize the time spent writing the reports, so more time can be spent inspecting
This is where digital data management comes in

6. What is Digital Data Management?
What are the issues?
Not all inspections are with digital gauges
Surface condition – SA2½
Surface cleanliness
soluble salts
beading
weld spatter
Surface contaminants
Oil, grease, dust
abrasive inclusions
Edge radii
Surface profile
Climate conditions
Dry film thickness
Film continuity
Damage & inclusions
Some use ‘mark 1 eyeball, others mechanical, and some have a digital display but no data output or memory

7. Digital Data Management Software for Inspection
Advantages:
Significantly speeds up measurement and recording time- by as much as 70%
Minimizes (and in most cases removes) human error- transcribing or keying in errors
Reduces paperwork
Provides real time inspection data to the customer

8. What is Digital Data Management?
Digital Data Management comes in many forms:
Hand written reports – scanned into the computer and stored
Hand written reports – manually keyed into the computer
Inspections using digital test equipment and downloaded into a computer
Inspections carried out using a PDA and digital test equipment ed to the PC
Total paperless QA – with inspection task planning

9. Total Paperless QA
Provides a framework for planning and recording coating inspection tasks
Provides a single point of reference for all coatings applied – and in which location
Provides a daily activity log
Generates a complete inspection report – automatically
Provides an electronic method for recording both digital and non-digital inspections
Maximises inspection time

10. Using Digital Data Management
Provides a framework for planning and recording these coating inspection tasks on large projects.

11. Key Components of Digital Data Management Software
A coating library
Defined coating systems used throughout the structure
A register of inspectors and their certifications (e.g. PCI and NBPI)
A list of individual inspection check/hold points
Details of the structure being coated (including drawings)
A list of individual inspection tasks, along with areas to record results and links to rework
A daily log that contains inspection information recorded by the system administrator

12. Coating Library
Repository of information from the manufacturer’s product data sheet
Manufacturer
Product name
Product ID
Specified wet film thickness/dry film thickness
Specified surface profile
Ambient conditions for application

13. Defined Coating Systems
Unique IDs in the coating library tying each coating system to structure area

14. Defined Coating Systems: Application
Once the coating system’s unique identification is created, the steps for proper coating application are specified

15. Register of Inspectors
Holds the records for approved inspectors:
Photograph of inspector
Copy of inspector’s certificate
Record of certificate expiration date
Details of where inspector has permitted access

16. Inspection Regime
Area in the digital data management system that groups inspection check points together, for example:
Surface Preparation Check Points
Removal of oil and grease
Removal of surface contaminants
Surface profile
Abrasive cleanliness
Cleanliness of abrasive blasting air

17. Steel Structure Details
A record of the steel structure and steel parts
Provides a basis for planning the job and inspection tasks

18. Steel Structure Details
Example:
Ship Structure
Record of:
Hull number/IMO number
Customer’s name
Ship’s name
Contract date
Keel-laying date
Planned launch and delivery dates
Gross tonnage
Deadweight
Length of ship
The beam
The draft and depth

19. Steel Structure Details
Store drawings of the structure as “jpg.”
Highlight individual areas of the structure as part of the structure definition
Assign the proper coating system to be applied to individual areas as well as the appropriate registered inspector

20. Steel Structure Details

21. Steel Structure Details

22. Inspection Tasks
The inspection record (inspection tests and results) is created after the structure part, coating system, and assigned inspector are identified

23. Daily Log
Documentation of inspection tests performed on a given day as well as any scanned documents
Should include supporting photographs as well as measured data

24. Reporting Inspection Test Results
Written on a hard copy printout of the inspection task
Transferred electronically to a Smart Phone/PDA
Entered directly into a computer

25. Reporting Using a Hard Copy Printout
Finished written document is scanned to create an electronic file within the digital management software

26. Reporting Using a Smart Phone/PDA
Transfers the inspection test results along with any photographs to the portable device

27. Reporting Using a Computer
Enter testing results directly into the computer

28. The Three Digital Inspection Techniques
Surface Profile
Ambient Conditions
Dry Film Thickness

29. Surface Profile
The roughened surface that results from abrasive blast cleaning or power tool cleaning to bare metal
A measurement of the peak-to-valley height of the surface roughness

30. Surface Profile
ASTM D 4417, Standard Test Method for Field Measurement of Surface Profile of Blast Cleaned Steel
Method B

31. Surface Profile ASTM D 4417, Method B
The depth of profile is measured using a fine pointed probe at a number of locations and the average is determined

32. Ambient Conditions
Weather conditions at a specific place and time or time period:
air temperature
relative humidity
dew point
wind velocity
Monitored on the job site

33. Ambient Conditions
Measured using:
Electronic dew point meters

34. Ambient Conditions

35. Ambient Conditions Maximum relative humidity of 85%
Surface temperature typically must be at least 5°F/3°C above the dew point in order for final surface preparation and/or coating work to begin or to continue

36. Dry Film Thickness
Depth of cured film usually expressed in mils (0.001 inch) or microns (millionths of a meter)

37. Dry Film Thickness
Measured with:
Type II Gage (Non-Destructive)

38. Dry Film Thickness Gages

39. Dry Film Thickness Standards
ASTM D 7091, Standard Practice for Non-Destructive Measurements for Dry Film Thickness of Nonmagnetic Coatings Applied to Ferrous Metals and Nonmagnetic, Nonconductive Coatings Applied to Non-Ferrous Metals

40. Dry Film Thickness: SSPC PA 2
Measurement of Dry Coating Thickness with Magnetic Gages
Type II Gages
Describes how many measurements to take in a given area

41. SSPC-PA 2 Provides guidance on: Frequency of verifying gage accuracy
Frequency of measurements (number of measurements to obtain based on the size of the coated structure
Places limits on thickness readings vs. specified thickness
Procedures supplement manufacturers’ operating instructions but do not replace them

42. SSPC-PA 2 Gage Reading- a single reading at one point
Spot Measurement- the average of at least three gage readings made within a 1.5 inch diameter circle

43. SSPC-PA 2
Make five separate spot measurements spaced arbitrarily over each 100 ft2 area to be measured
For structures NOT exceeding 300 ft2, each 100 ft2 area shall be measured
For structures NOT exceeding 1000 ft2, three 100 ft2 areas shall be arbitrarily selected

44. SSPC-PA 2
For structures exceeding 1000 ft2, the first 1000 ft2 shall be measured as stated in previous slide
Each additional 1000 ft2 of area or increment thereof, one 100 ft2 area shall be arbitrarily selected

45. SSPC-PA 2

46. Conformance Minimum Thickness
No single spot measurement in any 100 ft2 area shall be less than 80% of the specified minimum thickness
Note- it is possible for any single gage reading to under-run by a greater amount

47. Conformance Maximum Thickness
No single spot measurement in any 100 ft2 area shall be more than 120% of the specified maximum thickness
Note- it is possible for any single gage reading to over-run by a greater amount

48. Summary
Using digital data management can reduce time spent on the inspection process and overall project costs while providing an electronic record of the job in all its stages.

49. Conclusion
This concludes our webinar for today. Please join us for our next webinar, Coating Selection for the Wastewater Industry on October 20th at 1 pm EST