Comparison of Documentation Hold Point and Quality Control

Comparison of Documentation, Hold Point and Quality Control Training Requirements in SSPC Contractor QP 1, QP 3, QP 6 and QP 8 Standards Alison B. Kaelin, ASQ-CQA KTA-Tator, Inc.

Introduction Webinar Content: Ø General Overview of SSPC QP (PCCP) standards Ø Overview of scope and content of QP 1, QP 3, QP 6, QP 8 Ø Comparison of requirements for: Ø Personnel Training Ø Initial Ø Refresher Ø Summary of Required Programs, Technical Capabilities, Quality Control and Safety and Health Ø Required QC Documentation

Learning Objectives/Outcomes • Completion of this webinar will enable the participant to: Ø Describe overall QP 1, QP 3, QP 6, QP 8 requirements Ø Describe the training requirements for personnel for each standard Ø Understand the minimum program requirements Ø Understand minimum hold points and documentation requirements

SSPC Contractor Certification Program • Based on consensus standards • Only nationally recognized program for – pre-qualification – independent contractor evaluation • Each program reviews the painting contractor's ability to provide quality work in compliance with applicable safety, health and environmental standards

Types of SSPC Contractor Certifications • QP 1 evaluates contractors who perform surface preparation and industrial coating application on steel structures in the field (2008) • QP 6 evaluates the qualifications of industrial thermal spray (metallizing) contractors in the field and shop (2010) • QP 8 certification evaluates the qualifications of contractors installing coatings or surfacing on concrete (2003)

Types of SSPC Contractor Certifications • QP 3 evaluates a contracting company's ability to perform surface preparation and protective coating application in a fixed shop facility (2010). • This is a joint AISC/SSPC Standard • Three categories of shop certification: – Enclosed Shop – Covered Shop – Open (Exposed) Shop

Why Do we Need Certified Contractors? • Contractor certification covers the entire organization not just specific individuals • Contractor certification verifies: – Has written program and procedures in place to achieve specified requirements – Staff meets minimum requirements for competence, awareness and training – Health, safety and environmental compliance – Minimum documentation requirements

Management Procedures • Each of the standards have requirements for “Management Procedures” • Management Procedures include: – Policy • Commitment for written policies on quality, safety, health and environmental compliance • Written procedures for disseminating information throughout the organization

Management Procedures (c 0 nt. ) • Organization and Personnel – Organizational Chart – Names, Titles, Duties and Job Descriptions – Biographical Information (QP 3 only)

Management Procedures (c 0 nt. ) • Administrative and Management Procedures – Financial Recordkeeping – Review of job specifications and bid documents – Procedures for regulatory compliance • Identify person responsible for tracking (QP 1 only) – Procedures of contract estimating, scheduling and cost accounting (QP 6 and QP 8 only) – Procedures for evaluating each job function and required training (QP 8 only)

Management Procedures (c 0 nt. ) • Administrative and Management Procedures QP 1 Only – Confirmation by CPA or equal of accounting practices – Procedure for distribution of specifications to employees – Information of business entity – Documentation that subcontractors comply with QP 1 requirements

Management Procedures (c 0 nt. ) • QP 3 only – Purchasing procedure and minimum data requirements – Subcontractor evaluations – Qualification and evaluation of vendors – Minimum quality records established – Material identification, storage and certification – Non-conformances and corrective and preventive action

Technical Capabilities • Each of the standards have requirements for “Technical Capabilities” that include: – Technical Resources and Libraries • Specific standards and resources are defined for each QP program – Procedures • Procedures for reviewing, logging and transmitting information related to the project to applicable personnel

Technical Capabilities (Cont. ) • Experience, Facilities and Equipment – List of current and recently completed projects including product, scope, personnel, equipment, etc. – Equipment maintenance and repair procedures and logs – Specific process and inspection instrument equipment (QP 3 only) – Facility plan and equipment lists (QP 3 only)

Technical Capabilities • Technical capability requirements related to personnel qualifications vary dramatically between standards and are discussed in multiple sections of each standard • Personnel Qualification requirements will be discussed by individual standards at the end of this webinar

Quality Control – Inspection Procedures • Each of the standards have requirements for written Inspection Procedures that include: – Applicable standards and specifications – System for maintaining records – Job specific equipment and calibration requirements – Inspection of each major operation or hold point

Quality Control – Inspection Procedures (Cont. ) – Managing, documenting and reporting Non conformances (QP 1, QP 3, and QP 6 only) – Adequate lighting (QP 8 only) – Concrete specific procedure requirements (QP 8 only) – QC Manual (QP 8 only) • Technical Requirements (ASTM D 6237) and calibration standards • Contract specific requirements – Corrective action process (QP 1 and QP 3 only)

Safety, Health and Environmental Compliance • Each of the standards (except QP 3) have requirements for written Safety and Health Procedures or Program that include: – Documentation of safety education meetings – Process for conducting hazard assessments – Process formal management review of safety records and plans on annual basis – Personal protection equipment – Accident reporting

Safety, Health and Environmental Compliance (Cont. ) – Documentation of safety education meetings – Process for conducting hazard assessments – Process formal management review of safety records and plans on annual basis – Personal protective equipment – Accident reporting – Safety and loss control (QP 6 and QP 1 only) – Provisions for first aid – Safety procedures for equipment

Safety, Health and Environmental Compliance (Cont. ) • Environmental Compliance (QP 1 and QP 8 only) Procedures addressing: – Disposal of hazardous waste – Disposal of waste water (QP 1 only) – VOC compliant materials (QP 1 only) – Protection of air, soil and water (QP 8 only) • Note: control of hazardous paint and debris related to lead and other toxic metals is covered in SSPC QP 2.

Personnel Qualifications QP 1 – Quality Control Supervisor Quality Control Inspector Experience 3 years protective coating industry experience 2 years field experience in protective coatings Training QCS course and SSPC Coating Inspection Training or equal Formal Training in the fundamentals of coating inspection including calibration verification and documentation

Personnel Qualifications QP 1 – Craft Worker Training • Current Standard requires implementation of formal written program addressing: – Skills assessment – Verification of qualifications – Training as needed • A revised standard is in the works and is expected in 2012 • The PCCP Committee initiated a CAS QP 1 Execution Plan in March 2011

Personnel Qualifications CAS QP 1 Execution Plan • Applicable to project greater than $50, 000 • January 1 through December 1, 2012 – Begin qualifying selected personnel within their organizations to become eligible to take the CAS Level II Interim Exam • January 15, 2012 – Have CAS Level II Interim staff OR – Submit a “CAS Execution Plan” with application • January 1, 2013 Have CAS Level II Interim staff

Proposed CAS Crew Definition for initial phase-in in 2013 • One CAS for minimum 5 crew members holding the blast nozzle and spray gun • If contract: – exceeds $50, 000 for painting – Scope of work includes abrasive blast cleaning or spray application – Industrial and Marine Steel/Metal Structures

Proposed CAS Crew Definition for initial phase-in in 2013 • CAS requirement can be waived when: – Owner-specifies craft worker certification (e. g. USN C-7; C-12, etc. ) – Owner exemption from craft-worker certification (e. g. MD SHA) – Crews with less than five craft-workers holding the blast nozzle and spray gun

Personnel Qualifications CAS QP 1 Execution Plan • January 1, 2013 – One (1) CAS Certified Level II-Interim craftworker on each painting crew, regardless of crew size, during blast cleaning and spray application (Atmospheric and Immersion Service) • January 1, 2014 – One (1) CAS Certified Level II-Interim craftworker to every three (3) non certified craftworkers (25%) on each painting crew

Personnel Qualifications CAS QP 1 Execution Plan • January 1, 2016 – 50% CAS Level IIInterim / crew • January 1, 2018 – 75% CAS Level II-Interim / crew • January 1, 2020 - – 75% CAS Level II-Full / crew

Personnel Qualifications CAS Interim Status Pre Requisite Item #1 Pre Requisite Item #2 Pre Requisite Item #3 Cert Exam Verifiable Work Experience Training Experience Pass written exam with Minimum 2, 000 hrs a 70% or greater and (equivalent to 2 years Process A pass hands-on exam work experience) with a 90% or greater 150 CAS hours of accepted formal training Pass written exam with Minimum 3, 000 hrs a 70% or greater and (equivalent to 3 years Process B pass hands-on exam work experience) with a 90% or greater N/A

Personnel Qualifications QP 3 – Quality Control Top Individual Quality Control Inspector Experience Minimum 1 year experience in surface preparation and application of complex coating systems Inspection of complex coating systems; familiar and proficient with responsibilities and use of inspection equipment and procedures Qualification Not defined By training and experience as defined by Firm and competencies assessed and documented Training Not defined Documented formal training by qualified in -house or external sourcesbased on ASTM D 3276, Standard Guide for Painting Inspectors (Metal Substrates)

Personnel Qualifications QP 3 – Production • Formal written program addressing: • Skills assessment • Verification of qualifications • Annual performance assessment • Training as needed • Meet contractual training requirements

Personnel Qualifications QP 6 • Job description and qualification requirements for personnel and • Documentation of training experience and work history of thermal spray supervisor (TSS), thermal spray inspector (TSI) and thermal spray operators (TSO) • Method for monitoring proficiency of workers and inspectors

Personnel Qualifications QP 6 – Thermal Spray Supervisor (TSS) Steel Knowledge Experience Concrete Thermal spraying per CS 23, QP 1 and QP 3 Thermal spraying of concrete per QP 8 and AWS C 2. 20 2 years management of SP 5 and SP 10 jobs 1 year experience and C-7 Training 16 hours theory/quality per CS 23 16 hours theory/quality per AWS C 2. 20 8 hours of documented theoretical, practical, and hands-on quality control instruments from TS supplier or equal Qualification (initial and every 2 years) under AWS C 2. 16 and C 23 by SSPC or equal

Personnel Qualifications QP 6 Thermal Spray Inspector (TSI) Thermal Spray Operator (TSO) Program for training, qualifying and certifying its thermal spray inspector Program for training, qualifying and certifying its thermal spray operator in accordance with AWS C 2. 16 *Definition implies training per CS 23, and ASTM D 3276 *Definition states qualification is documented by signed and dated certificate indicating type of equipment, coating and application performed

Personnel Qualifications QP 8 –Foreman and QC Job Crew Chief or Foreman Experience Training Quality Control Manager 2 years experience in concrete coating or surfacing installation as installer, superintendant, project manager, owner or technical representative Quality Control Inspector Not specified QC training (general) minimum 8 hours 2 -day (16 hour) curriculum on concrete, masonry and cementitious surfaces 2 -day (16 -hour) ACI course on concrete fundamentals N/A

Personnel Qualifications QP 8 – Quality Control Required Curriculum • Basic Components , Characteristics, Surface Properties • Reasons for Coating and Surfacing • Precautions regarding adhesion • Generic polymer coating and surfacing types • Repair techniques • Pre-preparation, surface preparation, application/installation, inspection and testing. • Required safety, health, and environmental

Personnel Qualifications QP 8 – Craftpersons • Implement a program to ensure that qualified persons perform work • If necessary, training must be available to workers, including training to meet regulatory requirements • Have a method for monitoring proficiency of workers performing work • Maintain documentation

Hold points and Documentation • The standards vary greatly on the level of detail related to requirements for hold points or documentation of inspection • QP 1 , QP 3 and QP 6 are very broad and generally require that the contractor ensures that each major operation (e. g. surface, preparation, primer, intermediate and topcoat application) is properly performed and documented on a daily basis or in accordance with project documents • QP 8 requires documentation per the QC manual, contract and as deemed prudent by QC personnel

Hold points and Documentation • Each of the standards audit checklists contain detailed lists of hold points and/or documentation required • The initial application for each standard may have additional requirements (that are not in the standard) – Certified contractors should review initial applications on an annual basis to stay informed of new requirements • Several audit checklists and applications have been revised in 2011

Initial and Annual Evaluations • • • SSPC reviews application and programs Schedules and performs office and field audit(s) Requires annual internal audit(s) by QP firms Performs annual scheduled field/office audits Performs random audits at any time If findings, contractors have to initiate Corrective Action Plan (CAPs) • Major findings or regulatory citations may trigger Disciplinary Action Criteria (DAC)

Job Notifications (QP 1 Only) • QP 1 requires that SSPC be notified of job in advance – Notification required within 15 days of contract award • There is an online system for notifications • The online systems prompts contractors to provide – – Security arrangements PPE requirements Directions Contact Information

Summary • During this webinar, we have: Ø Reviewed the purpose of the contractor QP programs Ø Described and contrasted the management procedures, technical capabilities, personnel qualifications required by each Ø Described hold points and documentation requirements Ø The SSPC website has a wealth of information that is updated frequently Ø http: //www. sspc. org/qp-programs/qp-for-contractors/ Ø Check audit checklists and initial applications for new information and requirements

Thank you for attending! Any questions? THE END