AMPP CCI-2 cheat sheet

Surface preparation grades per SSPC-SP 10/NACE No. 2 (near-white): at least 95% of surface free of visible residues, with staining limited to less than 5% of each unit area.

SSPC-SP 5/NACE No. 1 (white metal): 100% removal of all visible oil, grease, dirt, mill scale, rust, coating, and oxide; a uniformly gray-white finish.

SSPC-SP 6/NACE No. 3 (commercial blast): at least two-thirds of each unit area free of visible residues; staining permitted on the remainder.

Abrasive blast profile is measured by replica tape (press-o-film) or profilometer; common target for epoxy systems is 1.5-3.5 mil (38-89 µm).

Dew point rule: surface temperature must be at least 3 °C (5 °F) above dew point to prevent condensation during surface prep and application.

Relative humidity above roughly 85% or surface temp within 3 °C of dew point is a stop-work condition for most blast and coating operations.

Salt contamination is assessed by conductivity (Bresle method) or chloride test kits; soluble salts can cause osmotic blistering and premature failure.

Ambient conditions (air temp, surface temp, RH, dew point) must be recorded before, during, and after surface preparation and application.

Wet film thickness (WFT) is measured with a comb gauge; dry film thickness (DFT) = WFT × percent volume solids (e.g., 8 mil WFT × 60% VS = 4.8 mil DFT).

Magnetic pull-off and eddy-current gauges measure DFT on ferrous and non-ferrous substrates respectively; verify calibration on certified shims before and after use.

SSPC-PA 2 DFT acceptance: for a 5-mil specified system, each gauge reading must be at least 80% of spec and the average at least 100% of spec, with no reading above the maximum.

Holiday (pinhole) detection: low-voltage wet-sponge for thin films; high-voltage spark tester for thicker or non-conductive coatings, with voltage set per film thickness.

Adhesion testing methods include cross-cut/tape (ASTM D3359), pull-off (ASTM D4541), and knife tests; destructive tests require repair of the test area.

Environmental monitoring during application records air temp, surface temp, RH, and dew point; solvent-borne coatings may require ventilation for solvent removal.

Stripe coats are applied by brush to welds, edges, corners, and fasteners before full spray application to build film at difficult geometry.

Recoat windows: exceeding the manufacturer's maximum recoat interval may require surface abrasion to ensure intercoat adhesion.

Generic systems: inorganic/organic zinc-rich primers for immersion or severe service; epoxy mid-coats for barrier and adhesion; polyurethane or polysiloxane topcoats for UV and color retention.

Volume solids (VS) determines wet-to-dry film relationship and theoretical spread rate: spread rate (ft²/gal) = 1604 × VS% ÷ DFT in mils.

Zinc-rich primers protect steel by galvanic (cathodic) action; zinc dust content typically exceeds 80% by weight in the dry film.

Epoxies provide excellent barrier and chemical resistance but chalk and yellow under UV; they are unsuitable as exterior topcoats without a UV-stable finish.

Polyurethane and polysiloxane topcoats offer UV stability and gloss/color retention; polysiloxane can achieve high-build single-coat finishes.

Coal tar epoxies and coal tar urethanes offer water resistance for immersion but have environmental and worker-safety restrictions.

Specification documents define surface prep standard, coating system, DFT ranges, environmental limits, and inspection hold points; the governing standard is cited by number and edition.

Coating selection considers service environment (C1-C5/Im per ISO 12944), substrate, expected service life, and application constraints.

Inspection reports must be factual, contemporaneous, and traceable: record date, time, location, ambient conditions, instrument readings, and inspector identity.

Nonconformance reports (NCRs) document deviations from specification with objective evidence, disposition, and corrective action tracking.

Hold points and witness points are defined in the inspection and test plan (ITP); work may not proceed past a hold point without inspector sign-off.

Calibration records for DFT gauges, hygrometers, and holiday detectors must be current and traceable to a recognized standard.

Ethical conduct requires independence, avoiding conflicts of interest, reporting only observed facts, and refusing to sign for work not inspected.

When specifications conflict, the more stringent requirement or the contract-specified hierarchy governs; document the conflict and resolution.

Referenced standards (SSPC, NACE/AMPP, ASTM, ISO) are cited by full designation and year; superseded editions must be identified.

Records should be legible, permanent, and retained per contract; corrections are made by single-line strike-through with initials and date, never erasure.