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Special Provisions AppendixQuality Control Programfor Coating of Steelwork

Bridge Engineering Branch Document No. 0750B.DOCRevision: May 1995

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APPENDIX

QUALITY CONTROL PROGRAM FOR COATING OF STEELWORK

1.0 FOREWORD

This Appendix outlines the Quality Control Program required by the Ministry of Transportationand Highways for any Contractor undertaking the coating of steelwork on bridges.

The term "Quality Control" defines those activities that the Contractor performs to conform withthe contract.

The term "Quality Assurance" defines those activities that the Ministry performs to ensureconformance with the contract.

The Quality Control Manual contains statements of the Quality Objectives and Policies that theMinistry considers essential for successful and economical quality management. The QualityControl Manual also outlines the Procedures and Documentation to implement and confirm thatthe Objectives are met.

The provisions of the Quality Control Program set forth in this manual shall apply to all coatingcontracts of steel bridge components contracted by or for the Ministry, unless the contract valuerequires the Contractor to be certified under the Steel Structures Painting Council's (SSPC)Certification Program.

This Manual requires the establishment of a Quality Organization with the RESPONSIBILITY forthe successful and timely implementation of all necessary Quality Control activities. Some

positions shown in the suggested Organization Chart may be held by the same individual. Forexample, the General Manager may also be the Contract Administrative Manager and thePurchasing Manager. The Superintendent may also be the Receiver and the Preparation &

Application Foreman.

2.00 QUALITY OBJECTIVES AND POLICIES

2.01 QUALITY OBJECTIVES

The Quality Objectives of the Ministry of Transportation and Highways cover all coating contracts

performed under contract to the Ministry.

The First Objective is that completed products shall conform fully to the governing Codes andSpecifications stipulated in the contract document.

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The Second Objective is that the Quality Control Program shall be fully integrated into theongoing coating activities of the Contractor.

The Third Objective is that the operations of the Quality Control Program shall protect theinterests of the Ministry with respect to scheduled completion date and contracted price.

2.02 QUALITY POLICY

It is Ministry Policy that the interests of the Contractor and the Ministry coincide when anapplication meets the Quality requirements of the contract, is completed on time, and isperformed in a cost-effective manner.

The Quality Control Program is an essential part of this Policy. It is based on the fact that thebest way to do any job is to do it right the first time. This applies to all stages of materialsprocurement, surface preparation, coating application and testing of each coating.

Quality Control involves all Ministry and Contractor personnel. Their activities must be consistentwith the Quality Objectives of the Contract.

A Quality Control Manager shall be appointed by the Contractor with defined responsibilities inresolving quality matters and shall report to a senior management level. At each hold point, theQuality Control Manager shall:

- Document the successful completion of each stage.- Identify and report non-conforming stages.- Initiate or recommend corrective action.- Verify corrections.

Quality Control is the responsibility of the Contractor. Unless monitored by a full-time Qualtity

Control Inspector, the Contractor shall assign a person to prepare all prepared documentation. Inthe event that quality control has produced results in a pattern of non-conformity, the Contractorshall, at the Contractor's own expense, install a qualified Quality Control Inspector who isindependent of the production crew. In establishing the non-conformance pattern, Quality Auditsshall not reveal any unreported non-conformities after the third day of operations.

The Quality Control Program is not subordinate to procurement, preparation, application ortesting activities. IT IS AN ESSENTIAL PART OF THEM.

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Special Provisions AppendixQuality Control Programfor Coating of Steelwork

Bridge Engineering Branch Document No. 0750B.DOCRevision: May 1995

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3.00 SUGGESTED ORGANIZATION CHART4.00 SCOPE

4.01 This Quality Control Manual governs the coating of steel bridges for the Ministry of Highways.

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4.02 The General Manager shall be responsible for adhering to this Quality Control Manual in allrespects.

4.03 The General Manager is responsible for ensuring that completed coating applications shallconform fully to the applicable codes stipulated in the Contract.

4.04 The General Manager is responsible for ensuring that all required documentation is producedaccording to this Quality Control Manual.

5.00 RANGE OF CAPABILITY

5.01 Within the Company, there is the necessary knowledge, skill (in-house or on a contract basis)and equipment to do the following work on the coating of steel bridges:

Design and prepare scaffolding drawings.

Design and install environmental enclosures to suite the requirements of all environmentalagencies.

Order, receive, check and store materials for use.

Prepare surfaces by cleaning, washing, flushing and abrasive blasting.

Measuring ambient conditions suitable for application.

Mixing and applying the various coatings.

Measuring application thickness and lapse time.

Resolution of all non-conformances, including procedures and proper tools.

Documentation of all stages of work.

6.00 MATERIAL CONTROL

6.01 All materials for the preparation and coating of bridges shall be ordered by the PurchasingManager in full conformance with the drawings and specifications.

6.02 The Purchase Orders shall contain all information necessary to ensure that materials purchasedcomply fully with the terms of the Contract. Batch numbers, Material Safety Data Sheets and

Product Data Sheets are required; it shall be so stated on the Purchase Order. Instructions shallstate when the certificates and reports are to be delivered to the Contractor.

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6.03 If a supplier proposes to substitute for any material, the Purchasing Manager shall refer theproposed substitution to the Contract Administrator for review. If the substitute is acceptable tothe Ministry, the Contract Administrator shall approve the change to the Purchase Order.

6.04 The Receiver shall inspect all materials on arrival for conformance with the Purchase Orders.They shall be properly stored in segregated areas for use on the Contract.

6.05 The Receiver shall report any non-conformances such as overage, shortage or damage to thePurchasing Manager and Quality Control.

6.06 The Purchasing Manager shall deliver all documentation to the Quality Control Manager forinclusion in the Quality file for the Contract.

7.00 INSPECTION AND REPORTING

7.01 The Quality Control Manager shall ensure only documented materials are used for the contract.

7.02 All surface preparation shall be done according to Contract Special Provisions and Section 216Standard Specifications for Highway Construction.

7.03 All coating applications shall be done in strict accordance to Contract Special Provisions, Section216 of Standard Specifications for Highway Construction, and the Manufacturer's specifications.

7.04 The Quality Control Manager shall file a written report of verification with the General Managerand report any non-conformance that may exist on any of the above items in Section 7.01 to7.03.

8.00 CORRECTION OF NON-CONFORMITIES

8.01 When a non-conformance is encountered, the Quality Control Manager shall determine arecommended procedure and obtain the Ministry's approval as quickly as possible beforeproceeding.

8.02 If there is non-conformance to the material specification stipulated in the Purchase Order, thePurchasing Manager shall immediately find out the reasons for the delivery of non-conformingmaterials. If the coating is the wrong color, age or temperature application, or the blasting grit isincorrect, the Quality Control Manager shall be notified immediately for verification that thematerial is an acceptable alternative in all respects. This verification shall include consultationwith Ministry. If the materials are not as specified, they shall be rejected and the correct materialshall be obtained.

8.03 If there is non-conformance of material delivery that will delay application, the ContractAdministrative Manager and Superintendent shall be notified immediately. They shall be givenrevised delivery dates for the adjustment of scheduling. The General Manager shall determinethe alternatives available and shall notify the Ministry.

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Special Provisions AppendixQuality Control Programfor Coating of Steelwork

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8.04 If there are post application non-conformities such as thickness, sags, runs, holidays, pinholes,orange peel, shadowing or poor coverage at rivet heads, bolts, plats, edges, crevices, pocketscorners or re-entrant angles, the Quality Control Manager shall notify the General Manager.They, along with the Superintendent, will submit corrective action to the Ministry for approval.

9.00 QUALIFICATIONS OF PERSONNEL & EQUIPMENT

9.01 Sandblasters and applicators shall be certified trades qualified (TQ) or Journeymen andapprentices as required by the Apprenticeship Branch of the Ministry of Advanced Education,Training and Technology.

9.02 Equipment shall satisfy the contract Special Provisions, as well as Section 216. Painting of SteelStructures in the Standard Specifications for Highway Construction.

9.03 Quality Control personnel shall hold a National Association of Corrosion Engineers (NACE) Level

1 Certificate as a minimum.

9.04 All Quality Control personnel shall have in their possession the contract drawings andspecifications, including Standard Specifications for Highway Construction, Guidelines for theProtection of Fish and Fish Habitat During Bridge Maintenance Operations in British Columbiaand have access to the latest edition of Volume 1 and 2 of Steel Structures Painting Manualpublished by Steel Structures Painting Councils (SSPC).

10.00 RECORDS RETENTION

10.01 The Contractor's Record File for each Contract shall contain the pertinent drawings, purchase

orders, bills of material, test reports, Quality Control documents, and certificates of compliance.

10.02 A copy of the Contractor's Daily Record file shall be presented to the Ministry's Representative ona daily basis.

10.03 Items in the Contractor's Record File shall be retained as per company policy.

10.04 The Quality Control Manager shall ensure that each file is complete in all respects before it isplaced in the Company archives.

11.00 HOLD POINTS

11.01 In planning the work flow, it is essential to coordinate with the Ministry Quality AssuranceInspector to decide "hold" points for inspection. A list of "hold" points shall be drawn up by theContractor and the Ministry at a meeting prior to the beginning of any work.

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Special Provisions AppendixQuality Control Programfor Coating of Steelwork

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11.02 The "hold" points will typically include some of, but not be limited to, the following:

- detergent cleaning- power washing/flushing- hand and power tool cleaning- abrasive blast-cleaning- prime coat- stripe coat- mid coat- top coat- clean up.

11.03 It must be understood that work will not proceed past a "hold" point until it has been signed off byQuality Control and Quality Assurance.

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SAMPLE COATING INSPECTION REPORT

NAME OF BRIDGE: ______________________ REGION: _________________________BRIDGE NO.: _______________________________ DISTRICT: _________________________CONTRACT NO: ____________________________ SPAN OR SECTION: ________________DATE: ____________ TIME STARTED: ____________ TIME FINISHED:____________WORKERS ON SITE: _______________________________________________________________EQUIPMENT ON SITE: _______________________________________________________________

_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

AMBIENT CONDITIONS

TIME TIME TIME TIME TIME TIME TIME TIME

Air Temperature

Wet BulbRelative Humidity

Dew Point

Steel Temperature

ABRASIVE BLASTING

TYPE AND GRADE OFABRASIVE:___________________________________________________________________________

ANCHOR PROFILE MEASUREMENTS

(ATTACH REPLICATAPE):______________________________________________________________

ABRASIVE CHECK FORCLEANLINESS:_______________________________________________________________________

AMOUNT OF ABRASIVE USED? (APPROX.): _____________________________________________

DEGREE OF CLEANLINESS AS PER SSPC AT TIME OF COATING: __________________________

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COATINGS

COAT PAINT MANUFACTURER'S

NAME AND DESCRIPTION

BATCH NUMBER

A B

APPLICATION PRESSURE

AIR Airless

COLOR VOL. USED

(LITRES)Primer

Stripe

Mid

Top

COAT D.F.T. BEFORE THIS COAT W.F.T.MEASUREMENTS

MIN MAX D.F.T.MEASUREMENTS

Primer

Stripe

Mid

Top

COATINGS

MIXING METHOD: ______________________________________________________________________________

THINNING (% OF TOTAL): _______________________________________________________________________

TYPES OF WORK PERFORMED: ___________________________________________________________________

NON-CONFORMITIES AND REPAIRS: _______________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

OTHER COMMENTS: ____________________________________________________________________________

_____________________________________________________________________________________________

_____________________________________________________________________________________________

QUALITY CONTROL __________________________ QUALITY ASSURANCE ______________________________

DATE: ___________________________________ DATE: ___________________________________________

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