Contract Specific QA/QC Management Plan for abrasive blast cleaning and the application of protection coating

Last Updated 3 weeks ago by Kenya Engineer

1.0 INTRODUCTION

This Article details an example of a the “Contract Specific Quality Management Plan” for abrasive blast cleaning and the application of protection coating. It outlines the components of the protective system and details the methods of reporting to ensure the installation is of the highest standard and quality achievable for the function the system is to serve. This document relates to Australian conditions, however with other jurisdictions there will be a need to check local regulations. Whilst this document relates to Australian conditions with changes the overall principles would apply to other similar industrial operations.

2.0 SCOPE OF QA / QC

2.1 The scope of the Management Plan as outlined in this document shall be limited to the site preparation, application and finishing topcoats of the specified protective coating system. (Eg. Zinc phosphate epoxy primer & Epoxy mastic topcoat)

The procedures shall pertain to:

(A) Surface Preparation.

Abrasive blast cleaning of the nominated steel work.

(B) Prime Coating

Application of the specified prime coat for protective system

Application of the specified topcoats for the overall protective System.

Essential Quality Control Features shall be dealt with as outlined in the following sections of this work method statement.

QUALITY CONTROL MANAGEMENT STRUCTURE

The Project Manager will have responsibility and authority to aid in all matters contained in this manual.

The operations and quality control management structure is as follows:

Quality Control Officer has a direct interface with operations on matters of training as to standards and workmanship, however he reports to the appropriate Project Manager who in turn is responsible to the Managing Director.
Supervisors and foreman are responsible for the quality of workmanship produced.
The Quality Control Officer is also responsible to the Project Manager for the quality assurance function of the procured materials including the quality audit at the suppliers factory, if and where necessary.

3.0 MANAGEMENT STRUCTURE

3.1 PROJECT MANAGER

The Project Manager is responsible for organising the project so that the completed work meets specified contract requirements.

He is responsible for ensuring customer requirements have been met by implementing the established inspection and testing activities and verifying their satisfactory results. He shall via the Quality Officer, oversee verification activities by the customer or testing authority, as required. The Quality Officer on some sites may also be the Project Manager.

3.2 QUALITY OFFICER

The Quality Officer, where specifically appointed, reports to the Project Manger on all quality related matters. He is responsible for the effective operation of quality system and maintenance of quality system documents to meet the contract requirements.

The Quality Officer is authorised to require all employees to comply with the provisions of the quality system and may issue instructions to that effect. He has the delegated authority from the Project Manager to restrict further work until a satisfactory solution has been obtained and implemented.

3.3 FORMAN

The Forman is responsible for co-ordinating and implementing activities at the project site which involve direct labour and/or where applicable, subcontractors, and is responsible for completing and detailing inspection & test documents.

3.4 LEADING HANDS

Leading Hands were appointed, have effective control of all site labour under their control.

3.5 TRADE OPERATORS

Each Operator is responsible for the satisfactory performance of his assigned duties under the direction of the Forman, or Leading Hand, as appropriate.

4.0 TENDER & CONTRACT EVALUATION

Prior to mobilization, Tender documents & work parameters shall initially be examined to ensure compliance with the tender enquiry document.

Selection and Recommendation for the project shall be based on evaluation of all the factors tendered, price, quality, time, method & proven ability to perform the work.

5.0 SITE PRODUCTION PROCEDURES

5.1 PROJECT PLAN MEETING

A meeting is to take place at the site of operations prior to the commencement of work. Those in attendance will be the, Project Manager, Quality Officer and Forman as required.

The meeting is to:-

Establish the production procedures which are to be operative on the site.
Ensure that all people are aware of the specifications that are to be applied.
Define the Quality Control that is to be imposed on the operations and the safety standards that are required.

The Project Manager will be responsible for ensuring that all people at the meeting have understood and are familiar with the requirements of the contract. He will also be responsible for the supply and site establishment of all production, quality control and safety equipment for the site.

5.2 MOBILISATION

The Project Manager is responsible for ordering the correct number of materials, organizing the establishment and the appropriate equipment in accordance with the Specifications Requirement.

5.3 OPERATION AND SURFACE PREPARATION EQUIPMENT

Before commencement of work, the daily maintenance check list to be carried out to ensure that the machinery is in good working condition.

Daily maintenance of machinery is the responsibility of the

Forman / Trade Operator.

The Forman are responsible for ensuring that fuels, abrasive, water, an inhibitor where necessary are available to ensure continuity of the work.

EQUIPMENT SERVICING

Equipment servicing shall be the responsibility of the Project manager/Forman to ensure that all servicing to machines, compressors spray equipment, blast hoses and sundry items are carried out on a regular basis. The servicing to conform with the standard procedures as laid down by the manufacturer and this company’s service policy. Regular servicing will prevent the possibility of equipment breakdown, loss of production, potential injury to working and/or adjacent personnel.

5.4 OPERATION OF SPRAY EQUIPMENT

The application of all paint will generally be carried out by airless or conventional spray, roller or brush. The Forman is to ensure that the equipment shall be suitable for the intended purpose, shall be capable of properly atomising the paint to be applied and shall be equipped with suitable water traps, pressure regulators, agitators and gauges. The air caps, tips, nozzles and needles shall be those recommended by the manufacturer of equipment and the paint manufacturer of or the products(s) being used.

When operators commence the daily application of paint, they are to check their techniques with a wet film thickness gauge to verify they are achieving a coating thickness which will produce the specified dry film thickness.

All mixing of paints and agitation, where nominated by the paint manufacturer shall be by means of continuous paddle type power agitators.

5.5 WEATHER CONSIDERATIONS

It is the responsibility of the Forman to ensure that work is not commenced or undertaken during times of inclement weather. Painting shall not be carried out in unsuitable weather conditions, such as high winds, rain and excessive temperatures or humidity’s etc.

5.6 WORKMANSHIP

It shall be the responsibility of the Forman to ensure that all works are carried out in a neat and tidy fashion. Work shall be carried out using the best trade practices and to the Project Manager’s satisfaction within the scope of the Specification. Forman shall be responsible to ensure that all operators are provided with the required clothing and safety equipment for the work to be carried out. On completion of the work the Forman shall ensure that all debris and waste materials produced during the contract have been removed.

5.7 SCOPE OF WORK (General)

Painting of T Flange sections

5.8 SURFACE PREPARATION

As defined by individual specification or contract document.

Eg. Abrasive blast cleaning – Australian Standard 1627 Part 4. whip blast.

5.9 COATING MATERIALS (Thickness Control)

Coating Materials shall be supplied and applied in accordance with the manufacturer’s specification. All coatings shall be applied to recommended wet film thickness to achieve minimum dry film thickness as specified

All trade operators involved in application of coatings shall possess wet film thickness gauges for determination of film thickness. All coatings shall be checked by applicators immediately following application to ensure that wet film thicknesses are achieved. Where film thicknesses require build up, they shall be brought up to thickness while the coating is still wet prior to any initial cure taking place.

In all cases the risk of overspray on surrounding or adjacent coatings shall be taken into consideration when determining method of application.

Topcoats shall be applied generally using either airless or conventional spray equipment or by other alternate approved methods, eg. brushing or roller application. All topcoats shall be applied in one coat unless otherwise specified and shall be applied to a recommended wet film thickness to achieve finished dry film thicknesses. Where adjacent steel work requires shrouding prior to application of topcoats and to prevent overspray, this shall be carried out by use of suitable shrouding materials i.e. plastic sheeting, drop sheets etc. Responsibility for assessment of dangers resulting from overspray will lie with the Project manger.

5.10 HANDLING, STORAGE AND TRANSPORTATION OF STEELWORK

It is the responsibility of the Project Manger through the Forman to ensure that all treated and painted steelwork when being moved by crane and/or sling, that the slinging operation and protection is such which will at all times minimise damage and that it should be carried out using the best trade practices and techniques.

6.0 SITE QUALITY CONTROL PROCEDURES

6.1 GENERAL

It is the responsibility of the Project Manager and Forman to familiarise themselves with this Manual and ensure that all instructions are rigidly adhered to.

6.2 SITE PREPARATION

The Project Manager is responsible for quality control via the Quality Officer and they are to instruct the trade operators through the Forman as to all masking of equipment that is required prior to commencement. They are required to inspect such masking and indicate approval for commencement of abrasive blasting by indicating so on the quality control report. Such comment can be made and initialled in the remarks section of the appropriate report by the inspecting officer.

6.3 RAW MATERIALS – INCOMING INSPECTION

It is the responsibility of the Project Manager to ensure that the coatings supplier has quality controlled the raw material to be supplied for the job in that such reports are available on demand prior to the commencement of coating procedures.

The Quality Officer shall undertake offsite quality assurance of the supplier’s product by random or regular inspection – at the manufacturer’s premises if necessary – of the supplier’s quality control programme and batch performance. Authorising certificates eg. NATA may be required to be furnished to clients and it is the Quality Officer’s responsibility to ensure these are provided by the relevant manufacturer/supplier.

All incoming coatings and materials shall be recorded on the appropriate job card with the following:

Manufacturer’s name
Product name
Batch numbers
GPC numbers and certificates

6.4 Inspection Procedures

GENERAL STATEMENT

The Forman will ensure that the four main hold points for inspection are observed. These are designated as:

(a) Prior to surface preparation

(b) After surface preparation

(d) After top coating

The condition of prepared surfaces shall be inspected by the Quality Officer on a routine basis to ensure confirmation with the specification and pictorial standards were appropriate.

Inspection for misses in primer will be carried out by the Quality Officer prior to application of topcoats. Any misses or pinholes will be rectified. The dry film thickness of the coating system will be checked by the Quality Officer by means of the appropriate paint film thickness instrument. These checks will be carried out on a routing basis on the day following application of topcoats, or after the appropriate drying period.

Ambient temperature and humidity conditions will be measured by the Quality Officer using a whirling hygrometer or other alternative approved units.

The Quality Officer will be responsible for ensuring that correct specification are applied to various parts of the steelwork. In particular, he will be responsible for recording of information on a standard quality control form. This information shall be recorded for various items of the steel work daily.

6.5 SURFACE PREPARATION STANDARD

Visual examination of the total surface will be carried out daily. Acceptance standard applied will be those detailed in AS1627.4 for dry blasted surfaces.

6.6 MEASUREMENT OF DRY FILM THICKNESS

Dry film thicknesses are to be measured using approved magnetic or electronic gauges. The equipment shall be calibrated on a regular basis (i.e.. Elcometer Model 246 or similar)

The frequency of dry film thickness measurements will be in accordance with appropriate standard as specified within contract documents.

6.7 ANALYSIS OF RESULTS

Humidity, Dew Point and Steel Temperature measurements will be used to make the following decisions:

For humidity above 35%.
For steel temperature less than 4 degrees Celsius above the dew points.
For steel temperatures above 40oC.
To proceed with prime coating prepared steel or the application of subsequent coats daily.

6.8 Non-Conformities and Correction

SURFACE PREPARATION

If the surface preparation does not meet the required standard, it is to be reworked in accordance with the specification and further checked until it conforms.

LOW FILM BUILD

A further coat of coating is to be reapplied to a re cleaned surface and the Quality Officer is to verify that the nonconformity has been eliminated.

COATING BREAKDOWN/RUSTING

Should coating breakdown or rusting occur which falls within the scope of the warranty then the coating will be restored in accordance with the specification in hand.

6.9 INSPECTION

Inspection or conformance will be conducted on the following basis at each hold point:

Forman – 100% of all surfaces
Quality Officer – Minimum 75% of all surfaces

DOCUMENTATION OF INSPECTION

Manufacturer, product name, batch number, surface temperature, humidity, film thickness, time am/pm, dew point. Refer to inspection & Test Plan Document.

FINAL INSPECTION

Final inspection of painted steelwork shall at a minimum include:

1) Dry film thickness

2) Continuity of film

3) Coating has good adhesion to the substrate

7.0 REPORTING VERIFICATION PROCEDURE

The Daily Report sheet is included. It will be completed daily, signed by the Quality Officer or Forman and presented to the Project Manager together with the I.T.P. (Inspection and Test Plan), on completion of contracted work.

8.0 RECTIFICATION, STOP WORK, AND CORRECTIVE ACTION

If during his duties the Quality Officer finds that work is not being performed in accordance with the specification or good trade practice he shall take the following action.

In the first instance, defects may be resolved by direct discussion between the Quality Officer and the trade operator concerned. To the extent that these discussions do not alter the basic work patterns, workload or output of the operator these discussions should result in immediate rectification of the defect.

Where the specification procedures are not being met and this cannot be resolved by direct discussion with the Quality Officer, the Forman shall be consulted. Resolution of any problem should be done in the spirit of team work rather that authority or conformation. The Quality Officer should seek to resolve any defects to the benefit of both the client and the team concurrently.

Where resolution cannot be reached between the Quality Officer and team leaders and the basis for a dispute exists, this shall be referred to the Project Manger for resolution.

8.1 GENERAL DISPUTES PROCEDURES

If a dispute arises between either the Quality Officer, operators and/or client and non-resolution of the dispute will require the work to be stopped, then the following action to be taken:-

The Forman is to be immediately informed.

The trade operators shall be moved as soon as possible to an alternative work location.

The Forman and Quality Officer shall all confer to resolve the dispute.

If a resolution cannot be achieved by consultation with the Quality Officer and Forman, where necessary, the problem shall be referred to the Project Manager.

Disputes shall be resolved as soon as possible in the interest of the client and ongoing production.

Where work subject to dispute in relation to quality control requires record a plan for rectification shall be resolved between the Forman and the Quality Officer. The rectification work shall then be carried out as soon as possible.

All corrective action shall be carried out on the understanding that all reworks must comply with the contact specification.

9.0 SAFETY PRACTICES FOR SURFACE PREPARATION AND SPRAY PAINTING

9.1 GENERAL

The following sets out instruction and information on aspects of safety for the site.

PRODUCTION

The Project Manager is responsible for all safety aspects to surface preparation and spray-painting work performed.

All employees engaged on this site are required to always meet the appropriate dress standards.

Employees under the influence of alcohol, narcotics or similar substances will not be permitted entry to the site. No intoxicating liquor, narcotics or similar substances are to be taken onto the site. Flighting and gambling are prohibited on site.

Employees are not in any way to interfere with or modify vehicles, plant or equipment without proper authority, i.e. compressors, machinery, airless or conventional spray equipment.

Employees who are using portable electric power tools are to ensure that an approved earth leakage unit is attached and that cords are in a serviceable condition.

All employees engaged in abrasive blasting and spray-painting operations should be conversant with the terminology used in the industry.

WORK PERFORMED AT HEIGHTS

When major operations are to be undertaken, such as blasting and painting of tankage, galleries, etc., scaffolding in the form of fixed or suspended platforms will be provided accordance with the appropriate regulations. All employees are expected to ensure that these scaffolds are adequately maintained, i.e. Kept clean and free from obstructions, no employee is permitted to make any alterations to any scaffolding or staging at any time. Alterations to scaffold or staging will be performed by licensed personnel only, under the direct supervision of the Project Manager or Forman.

ACCIDENTS AND INCIDENTS

All accidents and incidents no matter how small are to be reported to the Forman/Leading Hand immediately they happen in accordance with standard safety practices. The Project Manager shall fill in the appropriate report forms on the same day that the accident or the incident occurs.