The Role of the Inspector 4-1

Chapter 4: The Role of the Inspector

Objectives • To document the results
When this module is complete, the training The coating inspector’s responsibilities may
candidate will have knowledge and under- vary from job to job. For the purposes of
standing of: CIP, NACE has defined the inspector’s role
• The inspector’s responsibilities as that of a quality control technician who
is primarily responsible for observing and
• Team function
reporting the technical aspects of a coating
• Enforcing the specification project and its conformance or deviation
• Preparation from the project specification. Supervision
• Specification is not considered to be part of the inspec-
• Product data sheets tor’s role.
• Standards The general duties of the inspector are:
• Testing equipment • Observe
• Safety • Test
• Material safety data sheets • Verify conformance to specification (with
• Roles of quality assurance and quality documentation)
control • Report

Key Trade Terms 4.1.1 Observe

• Quality control technician Ultimately, the contractor is responsible for
• Materials inventory reports performing the work according to the project
• Instrument calibration history reports specification. The inspector should observe
and report the quality of the work per-
• Coatings specification
formed, noting its conformance or deviation
• Standards to the project specification. Inspectors
• Material safety data sheet (MSDS) should not direct the contractor on how to
• Quality assurance (QA) perform the work or make any changes to
• Quality control (QC) the project specification without written
authority. Doing so may lead to problems
4.1 The Coatings Inspector’s later in the project if issues regarding perfor-
Responsibilities mance and/or possible non-conformance.
The coating inspector’s responsibilities are: Inspectors should observe:
• To perform as a partof an effective team • The job site for safety issues that may
(as discussed in Chapter 3) affect themselves or the contractor
• To ensure that the project specification is
followed as written or formally amended

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4-2 The Role of the Inspector
Safety enforcement is not the
responsibility of inspector;
however, it is their responsibility contaminants (i.e., soluble salts testing)
to report any issues that may before surface preparation begins
affect the project. • Check the abrasive media to ensure that it
is the proper size and shape per the speci-
fication
• The weather conditions; observe, monitor
and document • Check abrasives for cleanliness
• The surface preparation • Check the air compressor for air cleanli-
ness with the blotter test
• The coating application
• Check the blast hose for proper air supply
• Coating cure priorto return to service
• Check the blast nozzle for size and wear
Watch closely for small things learned from
condition
experience and training that may cause prob-
• Check the blasted surface for proper sur-
lems with the project. This close, informed
face profile/anchor pattern
scrutiny assists the contractor as well as your
client. • Verify the blasted surface for the specified
level of cleanliness
4.1.2 Testing • Check the viscosity of the coating and its
All tests necessary, or required by the proj- temperature
ect specification should be done, to ensure • Examine the application equipment to be
the coatings project meets the requirements used; ensure that equipment is functional
and in good working order with correct
of the specification. Inspectors should also
setups
ensure that necessary test equipment is on
site, is properly calibrated, and functions • Check the DFT of each coat and verify
there are no drips, runs, or holidays
accurately.
• Check for surface contaminants between
Conduct tests honestly, accurately, and applications of additional coatings
openly. There should be no surprises and
The above list is merely an example of what
nothing to hide! Remember, Inspectors are
might be done for testing. There are various
part of a team whose goal is a successful
other tests that may be done throughout the
coating project. If there are issues or areas of
process. Specifications govern which tests
non-conformance that become evident dur-
need to be performed.
ing testing, relay this information to both the
contractor and your supervisor so appropri- Other items Inspectors need to monitor dur-
ate corrective actions can be taken. ing surface preparation and coating applica-
tion are:
Some tests that may be needed during sur-
face preparation and coating operations are: • Check the product data sheets and mate-
rial safety data sheets to ensure the proper
• Check ambient conditions for proper rela- paint is at the job site
tive humidity and dew-point parameters
• Check and document the batch numbers
• Ensure the surface temperature is in the
required range • Check the mixing process (this is an often
overlooked, but a critical step)
• Visually check for surface contaminants
and perform needed tests for invisible • Ensure adherence to proper induction time

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The Role of the Inspector 4-3

• Make sure pot life is not exceeded versely, this type of information is often lost
• Verify the recoat windows through a lack of or poor recordkeeping.
Some organizations do keep records, but
4.1.3 Verify and Document without the critical details, the records may
Conformance be of little value for determining the protec-
Performance and documentation of required tion afforded and the cost of protection per
testing and all work activities should be year. A company with a well-developed
done thoroughly, accurately, and consis- coatings program (including ongoing main-
tently, for the duration of the project. Inspec- tenance) benefits greatly from previous
tors should: detailed inspection reports.
• Ask the client’s representative if there are For example, a chemical plant producing a
any special reporting procedures required
variety of chemicals may use several generic
• Ensure there is agreement between the coatings throughout the facility based on
contractor and inspector about when and known or expected performance in similar
how to perform certain conformance tests
corrosive environments. With proper inspec-
• Agree on “hold points” before the project tion reports of previous coating projects,
begins
management could:
Coating inspectors are almost invariably
• Detect and tag design defects for review
required to provide the client with documen- by the engineering division for future
tation of the inspection. work
Documentation may include: • Evaluate coating performance
• A daily written report using standardized • Determine realistic annual cost data on
forms each coating system
• An inspection log or notebook to record • Develop a sound ongoing maintenance
all inspection activity program
• Routine reports Although personnel relocate in and out of a
• Notes from a weekly progress meeting company, records usually remain with the
facility. Good records can provide mainte-
• Other reports, as required by the client
nance departments with detailed information
Even if documentation is not specifically on:
required, good practice dictates that accu- • What was coated
rate, detailed records be kept. • What materials were used
Inspection records should show all environ- • When coating was done
mental conditions and activities involved in • How it was done
the pretreatment, cleaning, and application,
• By whom it was done
as well as all materials used.
• At what overall cost it was done
Good inspection documentation can provide
• What knowledge was retained in lessons
much valuable information for future learned
employees on the durability of coatings and
the economical protection they afford. Con-

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4-4 The Role of the Inspector

4.1.4 Report submitted periodically. The reports should

As noted earlier, always ask the clients’ rep- contain:
resentative about any special reporting • The name of the material
requirements or instructions they may need. • Quantity of onsite material
An important part of an inspector’s job is
• Material batch numbers
maintaining regular communication with the
owner’s representative and with the contrac- • Date of material’s arrival on the job site
tor. In addition to frequent, relatively infor- It is good practice for the contractor to use
mal conversations on the job, the truly coatings in a structured manner. Typically,
beneficial communication takes the form applicators do not do a very good job of
of regular reports and meetings. monitoring the batch numbers of material
Objective and professional records are used. As the inspector, it is good to ensure
important because they may be used for ref- that:
erence at a later date, and may even be • Coatings with thesame batch number are
examined in a court of law, if there are later kept together
disputes. Reports should contain accurate • First-in first-out (FIFO) rotation of materi-
statements of facts that are complete, clear, als is utilized
and concise.
4.1.5.2 Instrument Calibration
Exactly the type of reporting required from History Reports
the inspector should be identified in the Calibration reports normally contain infor-
coating specification or developed during mation on how frequently each instrument is
the pre-job conference. As noted previously, to be, or has been calibrated. Each instru-
a common understanding of specifications ment should carry a label clearly indicating
must be nailed down during the pre-job con- its serial number, or special label noting the
ference. The daily reports and routine date it was last calibrated. The inspector
reports generally are customized for each may be required to record on the daily report
project. the serial number of each instrument.

4.1.5 Other Reports 4.1.5.3 Weekly Reports

The more documentation that reports activi- In addition to daily reports, a weekly report
ties related to the project, the better for may be required. The weekly report may be
everyone on the team and project. Inspectors less detailed (i.e., a summary of the week’s
may elect, or may be required by the client’s progress and events), written in layman’s
representative, to maintain reports on such terms and in narrative form. Often it is writ-
things as materials inventory and instrument ten at the office rather than prepared by the
calibration history. inspector in the field. Copies of both daily
and weekly reports are given to the client,
4.1.5.1 Materials Inventory Reports the company doing the inspection, and the
These reports contain information on the onsite engineer to ensure that everyone is
inventory of job site materials, i.e., coatings, well informed about progress.
thinners, abrasives, etc., and are normally

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The Role of the Inspector 4-5

The weekly report may be used by the proj- depends on the inspector to observe and ver-
ect manager for his/her weekly progress ify that the project continues according to
report. There are at least as many recording the specifications and moves in a positive
formats as there are clients. Some forms direction.
require recording such items as:
• Location (general and detailed)
4.3 Verify Specification ─ Do Not
Change
• Contractor’s name and phone number
It is vital to understand that almost every
• Area (quantity) treated
user of coating inspection has a unique con-
• Dates of application cept of the duties and responsibilities of an
• Equipment list inspector. There seems to be no general
• Personnel agreement within the industry on the day-to-
• Quantities of abrasive and paint used day activities of inspection and the inspec-
tor. This is particularly true for independent,
third-party inspectors, who find job respon-
It is the coating inspector’s sibilities changing according to each client’s
responsibility to clearly understand point of view.
what records and reports are In addition to normal quality-control testing,
required. These items should be
some owners may regard the inspector as a
discussed and agreed on in the
project supervisor and assign non-inspector
pre-job conference.
duties such: as supervising labor, overseeing
safety issues, or keeping track of and order-
4.2 Team Function ing materials. Other owners may instruct the
inspector to simply observe the work, make
As discussed in detail in Chapter 3, it is tests and measurements, and report directly
extremely important the inspector knows the to the owner without any dialogue with con-
relationship responsibilities with the owner tractors or their workers. Conceivably, at
and the contractor (team work). Ultimately, some point, inspectors may be called on to
all parties should work in concert to do qual- function at either extreme.
ity work per the contract specifications.
Although inspectors specific responsibili- To reiterate, for the purposes of CIP, NACE
ties may vary from one project to the next, International has defined the inspector’s role
they are not typically expected to direct the as that of a quality control technician
contractor’s work. whose primary responsibility is to observe
the technical aspects of a coating project.
The inspector’s role is to work within the Supervision is not considered to be part of
team, as the owner’s representative and with the inspector’s role.
the contractor, to ensure the engineered life-
cycle is achieved according to the project Regardless of the responsibilities assigned to
specifications, design and contract require- the inspector, the specification is the docu-
ments. Generally, the owner is represented ment that governs any project. An inspec-
by an engineer or a project manager who tor’s primary responsibility is to “verify”

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4-6 The Role of the Inspector

the specification. The inspector does not • Workmanship

make changes to the specification for any • Application
reason. Changes to the specification may • Work schedule (sequence of work to be
only be made in writing by the owner or the done)
author of the specification at the owner’s
• Repairs and remedial coating work
direction. Inspectors should only follow
• Inspection
changes that are submitted in writing. Verbal
agreements of change can cause problems • Documentation
and should be avoided. As the inspector, ensure that none of the
listed elements are missing or, if present,
4.4 Preparation they must provide enough detail to do the
In order to do the job properly, inspectors job properly. For example, the specification
must be prepared for the specific job may address the proper DFT, but may not
assigned. Ensure any questions about the address how to handle areas of non-con-
project are answered before work begins. forming high or low DFT. This could create
The pre-job conference is the best opportu- confrontation on the job site. Ambiguity of
nity to get answers. For this reason, thor- issues like that should be addressed during
oughly review any information that can be the pre-job conference.
obtained before the pre-job conference and
complete a list of questions or concerns to 4.6 Product Data Sheets
bring to the meeting. Obtain the manufacturers’ product data
sheet (MPDS) or technical data sheet (TDS),
4.5 Specification read and fully understand the coating system
Always obtain, read and fully understand the required in the specification. The MPDS
coating specification. Be prepared to bring and/or TDS are prepared by manufacturers
up questions with the appropriate person and to answer many questions about their prod-
get them resolved. Most specifications are ucts. Manufacturers provide the MPDS for
formal, structured documents. A good coat- each coating product. Inspectors should
ing specification contains most or all of the always have copies of each MPDS on the
following sections, each with information job site during surface preparation and coat-
and criteria for the job: ing application.
• Scope of work Verify by date of publication that the most
• Terms and definitions recent copy is being used. Look for discrep-
ancies between the MPDS and the specifica-
• Reference standards and codes
tion. Inspectors can question these
• Safety discrepancies, but always remember the
• Pre-job conference written specification overrides the MPDS,
• Surface preparation unless written permission is given to go out-
• Coating materials (includes the coating side the specification and approved by the
schedule) owner’s project manager. Some specifica-
• Sampling coatings

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The Role of the Inspector 4-7

tions integrate the MPDS as part of the spec- 4.9 Safety

ification. Safety enforcement is not the responsibility
of inspectors. Safety is the responsibility of
4.7 Standards all workers on the job site. The employer has
Know the standards required in the specifi- the primary liability for safety, but Inspec-
cation and have copies of them readily avail- tors should be knowledgeable enough to rec-
able during inspection work. If the written ognize safety violations because both their
and/or visual standard(s) required are not at safety and the crew’s safety is at stake. All
hand, know how to obtain them. The specifi- observed safety violations should be imme-
cation should include a list of published diately reported to the proper personnel.
standards referenced by particular sections
or parts of the document. If it does not, this 4.10 Material Safety Data Sheets
is another issue that may be resolved during (MSDS)
the pre-job conference. Any part of a refer- The MSDS is an information form from
enced standard may be as binding on all par- manufacturers that contains data about
ties as the entire standard, unless an known substances in a particular product. It
exception is noted. is an important tool for workplace safety; its
purpose is to inform workers and emergency
4.8 Testing Equipment personnel about how to work with or handle
Some of the equipment needed to conduct the substance safely. It also includes infor-
inspections is listed below. In later chapters mation about:
these items are discussed and instructions
• Toxicity
given on how, when, and where to use them.
• Health effects
• Psychrometers (sling or electronic),
• First aid
including charts
• Reactivity
• Profilometer or Testex tape and anvil
micrometer • Storage
• Wet-film thickness (WFT) gauges • Disposal
• Dry Film thickness (DFT) gauges, includ- • Personal protective equipment (PPE)
ing: • Spill handling procedures
— Pull-off magnetic gauges Although the MSDS should be brought on to
— Fixed probe magnetic gauges the job site by the material handler, it is
• Holiday detectors, including: important that the inspector, for safety rea-
— Low-voltage DC (wet sons, knows where the MSDSs are located.
sponge) detector Be familiar with their data on chemicals that
— High-voltage DC detector workers may contact. The MSDSs should be
— High-voltage AC detector country- and supplier-specific. The same
product can have very different formulations
in different countries. The MSDSs of every

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4-8 The Role of the Inspector

material used must be kept onsite and avail-

able to site workers.

4.11 Roles of Quality Assurance

and Quality Control
The main role of the QA/QC inspector is to
verify the coating specification. The inspec-
tor must have a thorough understanding of
the specification, product data sheets, and all
other documents related to the project.

4.11.1 Quality Control

Quality control (QC) is similar to, but not
identical with, quality assurance (QA). QC
is a procedure or set of procedures intended
to ensure that a manufactured product or
performed service (i.e., installed coatings or
linings) adheres to a defined set of quality
criteria or meets the requirements of the cli-
ent or customer. It is usually performed by
contractors as part of their process.

4.11.2 Quality Assurance

During the development of products and ser-
vices, Quality Assurance (QA) is any sys-
tematic process that checks whether a
product or service being developed is meet-
ing specified requirements. A quality assur-
ance system is said to:
• Increase customer confidence
• Improve work processes and efficiencies
Quality assurance was initially introduced
during World War II when munitions were
inspected and tested for defects post produc-
tion. Quality assurance systems em-phasize
catching defects before they get into the
final product. “QA” is sometimes paired
with “QC” in a single expression called,
quality assurance and control (QA/QC). QA
verifies the permanence of the QC effort.

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The Role of the Inspector 4-9

4.12 Ethics Case Study “Hey, Simmons,” the contractor said “Look,
Razorback Industries is a large, diversified I really appreciate you helping me. Other-
company. The majority of its business, how- wise, I’d be there painting for another
ever, is in petrochemicals. month, and I have another big job starting up
in two days.”
Because of a recent plant expansion, exten-
sive coatings operations were done. A small “Well, if you were still here painting, I’d still
local contractor was hired to do the work. To be there inspecting, and I’m ready to start
cut his costs, the contractor arranged the spending my Saturdays at home,” John
work schedule so that every Saturday he replied.
came in by himself to spray paint. “Yeah, but a lot of guys would be real happy
John Simmons, an employee at one of to just sit and watch someone else work or
Razorback’s subsidiary plants for several slip out for a few beers while they’re wait-
years, works in the plant’s quality control ing. But you really were a big help to me.
department. When the coating operations Look, this is for you. I saved a lot of money
began, John was appointed Razorback’s sending the crew home on weekends, and I
newest coating inspector. could have lost a lot of money if I stayed any
longer. And it will really cost me money if I
While this involved a substantial increase in have to do any rework.”
his workload, there was no increase in pay.
He frequently had to work several hours John looked down at the brown envelope
overtime per day and had to come in every thrust at him, obviously filled with cash,
Saturday to inspect the work being done by with a $50 bill on top.
the contractor.
4.12.1 Attestation
“Boy, if I were getting paid for this, I’d earn Should John take the money? Why or why
a mint of money, but I guess working unpaid not?
days, nights, and weekends is a privilege of
Read the case study, discuss the situation
salaried management,” John thought to him-
with your team for no more than 20 minutes,
self more than once.
and write your conclusions on a flip chart.
Since he could leave as soon as the last of Select one member of the team to present
the work was inspected each day, John your team’s findings to the rest of the group.
began to give the contractor a hand with
You may record your team’s result in the fol-
minor things like arranging the hose line,
lowing space:
handing up the gun when the contractor was
working on scaffolding, and so on, in order
to speed things up so he could get home.
Finally, the project was finished. John had
finished his daily inspection, and, while fin-
ishing his summary final inspection report in
the field office by himself, the contractor
walked in.

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4-10 The Role of the Inspector

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The Role of the Inspector 4-11

Key Terms Definitions

Coatings Specification: A formal, struc-
tured document containing information on a
project (such as scope, terms, schedule,
inspection, etc.).
Instrument Calibration History Reports:
Reports that normally contain information
on how frequently each instrument is to be
or has been calibrated.
Materials Inventory Reports: Reports that
contain information on the inventory of job-
site materials, and are normally submitted
periodically.
Materials Safety Data Sheets (MSDS): A
form containing data of known substances in
a particular product.
Quality Assurance (QA): Any systematic
process that checks whether a product or ser-
vice being developed is meeting specified
requirements.
Quality Control (QC): A procedure
intended to ensure that a manufactured prod-
uct or performed service meets the require-
ments of the client or customer.
Quality Control Technician: The inspec-
tor’s role, primarily responsible for observ-
ing and reporting the technical aspects of a
coating project and its conformance or devi-
ation from the project specification.
Standards: A term applied to codes, specifi-
cations, recommended practices, proce-
dures, classifications, test methods, and
guides that provide interchangeability and
compatibility. Standards enhance quality,
safety, and economy; they are published by a
standards-developing organization or group.

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4-12 The Role of the Inspector

Study Guide

1. How does NACE define the inspector’s role?

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

2. What is the inspector’s responsibility when it comes to safety on a project?

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

3. Name some tests that may need to be conducted during surface preparation and coating
operations.
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

4. Name some of the documentation/reports that may be required to be maintained on a coat-

ings project.
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

5. What are the most important characteristics of a good report?

________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

6. What is the inspector’s primary responsibility and what should the inspector not do as it
pertains to the specification.
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

7. What type of information could you expect to find on a product data sheet?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

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The Role of the Inspector 4-13

8. What type of information could you expect to find on a material safety data sheet?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

9. Explain the difference between quality assurance (QA) and quality control (QC).
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________

©NACE International 2011 Coating Inspector Program Level 1

July 2011
 Chapter 4
The Role of the 
Inspector

1 of 18

The Coatings Inspector’s Responsibilities

• For the purposes of CIP the inspector’s role is that of a quality 
control technician responsible for observing and reporting 
conformance or deviation from the project specification.  

• Supervision is NOT considered to be part of the inspector’s 
role.

2 of 18

Observe
The inspector should be observing:
• Job site for safety issues
 Note:  Safety enforcement is not the responsibility of the inspector, 
however,  it is his/her responsibility to report any issues that may affect 
the project.

• Weather conditions
• Surface preparation 
• Coating application 
• Curing of the coatings

3 of 18

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 Testing
• All testing should be 
performed that is necessary, 
or required by the project 
specification.

• Ensure that all necessary 
test equipment is on site, 
properly calibrated and 
functions accurately.

• Conduct your test honestly, 
accurately, and openly.  

4 of 18

Verify Conformance 
& Document
• Documentation should be done thoroughly, accurately and 
consistently
• Inquire about any special reporting procedures
• Ensure that the contractor and you are on the same page as to 
when and how certain tests for conformance will be performed

5 of 18

Reporting
The inspector should maintain regular communication with 
the owner’s representative and with the contractor.

Inspector completing reports

6 of 18

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 Team Function
All parties should be working in concert to perform 
the work:
• Inspector
• owner’s representative
• contractor

7 of 18

Responsibility

Your primary responsibility as the inspector is to “enforce” the 
specification. 

The inspector is NOT to make changes to the specification for 
any reason.

8 of 18

Specification
A good coating specification will contain most or all of the 
following:
• Scope of work • Sampling coatings
• Terms and definitions • Workmanship
• Reference standards and  • Application
codes • Work schedule (sequence 
• Safety of work to be done)
• Pre‐job conference • Repairs and remedial 
• Surface preparation coating work
• Coating materials  • Inspection
(includes the coating  • Documentation
schedule)

9 of 18

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 Look for any elements of the specification that are missing or 
do not provide enough detail to help you to properly complete 
your job requirements.

10 of 18

Product Data Sheets

Obtain, read, and fully understand the 
Manufacturers’ Product Data Sheet (MPDS) or 
Technical Data Sheet (TDS) for the coating system 
required by the specification.

11 of 18

Standards

• Know the standards 
required
• Have copies of applicable 
standards available
• Specification should include 
a list of published standards 
referenced

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 Testing Equipment
• Have proper equipment for inspection tasks required
• Equipment in proper working condition
• Current calibration verifications

13 of 18

Safety
• Safety enforcement is NOT the responsibility of the inspector

• The inspector should be knowledgeable enough to recognize 
safety violations

• All safety violations should be immediately reported to the 
proper personnel

14 of 18

Material Safety Data Sheets 
• Procedures for handling /working with the substance in a 
safe manner

• Includes information such as toxicity, health effects, first aid, 
reactivity, storage, disposal, (PPE) and spill handling

• Inspector should know where the MSDS’s are located /be 
familiar with the MSDS’s

15 of 18

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 Roles of Quality Assurance 
and Quality Control
The main role of the QA/QC inspector is to enforce the coating 
specification.
Quality Assurance
Any systematic process of checking to see whether a product or 
service being developed is meeting specified requirements. Usually 
performed by a third party inspector.

Quality Control
A procedure or set of procedures intended to ensure that a 
manufactured product or performed service adheres to a defined 
set of quality criteria or meets the requirements of the client or 
customer. Usually performed by the contractor.

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Ethics Case Study
• Review the Case Study in the student manual
• Discuss the situation with your team for no 
more than 20 minutes
• Write down your conclusions
• Present your findings to the group

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Chapter 4
The Role of the 
Inspector

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Coating Inspector Program © NACE International
Level 1 Chapter 4
July 2011 ‐6‐