THE MOST ADVANCED AND INNOVATIVE METHOD OF COATINGS APPLICATOR TRAINING FOR THE SURFACE TREATMENT AND COATINGS INDUSTRY.

Transcription

1 THE MOST ADVANCED AND INNOVATIVE METHOD OF COATINGS APPLICATOR TRAINING FOR THE SURFACE TREATMENT AND COATINGS INDUSTRY

2 WELCOME TO Developed by industry experts who have researched global protective coatings in the Marine, Offshore, Construction, Petrochemical and Civil industries. It provides (trainee coating applicators) a comprehensive package of training modules that ensure professionalism and an insight into methods of surface treatment and application of protective coatings. The Trainthepainter training course is fully endorsed by SSPC the Society for Protective Coatings. SSPC: The Society for Protective Coatings was founded in 1950 as the Steel Structures Painting Council, a non-profit professional society concerned with the use of coatings to protect industrial steel structures. In 1997, the name of the association was changed to The Society for Protective Coatings to better reflect the changing nature of coatings technology and the ever-expanding types of construction materials. SSPC is the only non-profit association that is focused on the protection and preservation of concrete, steel and other industrial and marine structures and surfaces through the use of high-performance protective, marine and industrial coatings. SSPC is the leading source of information on surface preparation, coating selection, coating application, environmental regulations, and health and safety issues that affect the protective coatings industry. SSPC s core products and services include: Coatings industry standards Technical publications (books, videotapes, CDs) Training & certification courses Painting contractor certification programs Conferences and events Webinars Accredited internationally by Lloyd s Register, this training programme has been developed with the use of videos and innovative animations to allow accredited and experienced trainers to train and qualify students in the process of surface treatment. Protective Coating Applicators, Abrasive Blaster Cleaners Operatives and Sprayer Painters can be accredited with this advanced and internationally recognised training scheme. A dynamic, effective, comprehensive and advanced training programme. Theoretical and practical training and assessments are conducted in the classroom or a workshop environment to ensure the student gains a thorough understanding of the processes involved with surface preparation and coating application. This training course has been developed from basic principles to allow a new recruit entrance into the industry, training for an experienced person and education to lead hands, foremen, supervisors or third party personnel. All training units comprise of text, illustrations, animations, video and a voice over. Printable handout notes also accompany the training. The applicator training must be conducted by approved trainers who successfully complete the trainthetrainer course which has been specifically developed for the protective coatings industry.

3 A continuously updated dynamic training programme The trainer must possess the following qualifications and experience prior to attending the trainthetrainer course. 5 years experience in the protective coatings industry as a coatings supervisor, manager or inspector and: NACE Coatings Inspector Level 2, FROSIO Level 3, SSPC PCI Level 2 or ICorr Level 2 Note: an organisation may propose to use a senior manager who has relevant experience but no inspection qualifications. Industry qualifications such as a degree or equivalent will be considered by the Administration. Benefits to the Applicator The applicator training programme offers numerous benefits: Trained and competent staff Applicators work to the same set of agreed standards and procedures Health and Safety issues addressed Quality of work improves, which has the effect of increasing customer satisfaction Cost control and wastage issues are considered Applicators understand, appreciate and look after equipment Benchmarks are set for good practice, developing a sense of pride in achieving the required standards Applicators have an industry recognised and accredited qualification Morale of the applicator is increased having received training and accreditation in their trade As a result of the above, less claims for poor workmanship are received.

4 COURSE CONTENT Protective Coatings Application 1 Health and Safety 1.1 Company Induction 1.2 Accident Prevention 1.3 House Keeping 1.4 First Aid 1.5 Electricity and Air Supply 1.6 Permit to Work 1.7 Risk Assessment 1.8 Material Health and Data Sheets 1.9 LEL, TLV, OEL MEL and Ventilation 1.10 PPE (Inc RPE) 1.11 Basic Access Requirements (Inc Full Protection) 1.12 Safety in Surface Preparation 1.13 Safety in Paint Application 1.14 Method Statements (Work Instructions) 1.15 Confined Spaces 1.16 Health and Wellbeing 2 Access, Plant and Equipment 2.1 Erecting and Dismantling Platforms Erecting and Dismantling Platforms Safe Use of Ladders 2.2 Types of Mobile Access 3 Surface Preparation 3.1 Surface Preparation Requirements Types and Methods of Surface Preparation Types of Substrates and Materials Previously Painted and Coated Substrates 3.2 Surface Preparation Standards Mechanical and Hand Preparation Standards Pre-Surface Condition Pre-Surface Preparation and Cleaning 3.3 Hand and Power Tool Equipment Chipping Hammer Hand Wire Brush Scraper Needle Gun Power Wire Brush and Grinding 3.4 Pre-Cleaning Methods Steam Cleaning Water Washing Solvent Cleaning 3.5 Auxiliary Equipment Compressors Heaters Lighting Grit Removal and Hoppers De-Humidification 3.6 Water Jetting Introduction to High Pressure Water Jetting BS EN ISO SSPC VIS 4-NACE VIS 7 4 Paint Types 4.1 Coating Types and Systems 4.2 Products Data Sheets - Review 4.3 Single and Two Part Materials 4.4 Paint Mixing 4.5 Pot-Life and Induction 4.6 Storage 4.7 Batch Numbers 4.8 Volume Solids 4.9 Coverage 4.10 Compatibility 5 Paint Application 5.1 Environmental Conditions Relative Humidity and Dew Point Steel Temperature 5.2 Types of Paint Application Equipment Brush Application Roller Application Airless Spray (Introduction) Air Assisted Spray (Introduction) 5.3 Paint Film Thickness Wet Film Thickness Dry Film Thickness Drying and Recoating Stripe Coating 5.4 Paint Application Procedures Surface Cleaning Coatings Damage and Repair Materials and Equipment Handling 5.5 Paint Locations and Types Shop Painting Site Painting General Maintenance - Plant and Equipment Equipment Cleaning Maintenance Painting Operations 6 Quality Control 6.1 Environmental Conditions Inspection Equipment 6.2 Inspection Standards BS, EN, ISO, SSPC, NACE etc Visual Standards (Introduction) 6.3 Standards, Specifications and Codes of Practice 6.4 Paint Manufacture 6.5 Inspection and Test Equipment Inspection and Test Equipment Documentation 7 Metallic Coatings 7.1 Thermal Metal Spray for Corrosion Protection 7.2 Galvanizing

5 8 Intumescent Coatings 8.1 Thin Intumescent Coatings 8.2 Thick Intumescent Coatings 9 Concrete 9.1 Concrete Basics 9.2 Concrete Moisture 9.3 Concrete Preparation 9.4 Concrete Coatings 10 Environmental 10.1 Volatile Organic Compounds 10.2 Hazardous Waste 11 Coating Failure 11.1 Coating Failures 12 Management and Supervision 12.1 Management and Supervision 13 Offshore 13.1 Offshore Construction 13.2 Offshore Maintenance 14 Speciality Units 14.1 Specialist Coatings 14.2 History of Pipe Coatings 14.3 Fusion Bonded Epoxy Coatings for Pipeline Protection 14.4 Miscellaneous Pipeline Coatings and Field Joints 14.5 Rubber Linings 14.6 Special Coatings and Linings 14.7 Powder Coatings 15 Visual Standards 15.1 BS EN IOS BS EN ISO BS EN ISO BS EN ISO SSPC VIS SSPC VIS SSPC VIS 4 - NACE VIS SSPC VIS 5 - NACE VIS 9 Abrasive Blast Cleaning 1 Introduction 1.1 General Overview 1.2 Basic Corrosion 1.3 Mill Scale 1.4 Substrate Materials 1.5 Pre-Surface Condition 1.6 Mechanical Blast Cleaning Equipment 1.7 Types of Air Blast Equipment 1.8 Wet Abrasive Blast Cleaning 2 Health and Safety 2.1 Health and Safety (Introduction) 2.2 Method Statements / Risk Assessments 2.3 Personal Protection Equipment (PPE) 2.4 Breathing Air / Helmets 3 Blast Media 3.1 Types of Abrasives 3.2 Surface Profile 4 Standards and Quality Control 4.1 Visual (Photographic) Standards 4.2 Surface Cleanliness 4.3 Environmental Conditions 5 Operational Procedures 5.1 Compressed Air and Air Requirements 5.2 Blast Hose and Associated Equipment 5.3 Types of Nozzle 5.4 Ventilation and Lighting 5.5 Communication 6 Process Control 6.1 Equipment Set-Up and Testing 6.2 Abrasive Blast Cleaning Process 6.3 Abrasive Blast Cleaning Standards/Guides Spray Painting 1 Introduction 1.1 Paint Application (Introduction) 1.2 Basic Corrosion 1.3 Surface Preparation 1.4 Coating Types and Systems 2 Health and Safety 2.1 Material Safety Data Sheets 2.2 Risk Assessments 2.3 Method Statements 3 Paint Materials 3.1 Product Data Sheets - Review 3.2 Paint Storage and Paint Mixing 3.3 Quality Control 4 Airless Spray Equipment 4.1 Airless Spray Painting Equipment Airless Spray Painting Equipment - A Airless Spray Painting Equipment - B 4.2 Equipment Set-up, Testing and General Use 5 Conventional Air Spray 5.1 Conventional Air Spray Equipment 6 Plural Component Spray 6.1 Plural Spray Promoting professionalism, safety and efficiency within the coatings industry

6 SPRAY PAINTING The student will conduct a number of theoretical training sessions before conducting the practical training and assessments: Airless spray painting equipment Literature and instructions Health and Safety Design, use and maintenance Airless spray equipment set up, testing and general use Full set up of equipment Use and process of equipment Shutdown of equipment Health and Safety Personal protective equipment

7 TrainthePainter Administration Audit of Quality Management System Company Registration Pass Audit Licensed Organisation TraintheTrainer Course External Approved Trainer Approved Trainer Annual Audit TrainthePainter Course Protective Coating Applicator Abrasive Blast Cleaning Operative Spray Painter UNITS UNITS UNITS Theoretical Theoretical Practical 24 Practical 12 Theoretical 15 Practical 4 DURATION DURATION DURATION Theoretical 2-3 days Practical 1-2 days Theoretical 1 day Practical 1 day Theoretical 1 day Practical 1 day NOTES 1. The trainthepainter administration is responsible for the management of the training program. 2. The licensed organisation is the company who enters into a contract with the administration as a registered company. This can be a painting contractor, coating supplier or independent training organisation. 3. An audit of the quality management system and the facilities to undertake the theoretical and practical training is conducted on the company during the registration process. The company must possess a quality management system in accordance with BS EN 9001 or equivalent. 4. The trainthetrainer course is a comprehensive two day training program which has pre- requisites on the trainers with respect to their qualifications and experience. The course must be successfully completed before an approved trainer s certificate can be issued. 5. An independent annual audit will be conducted on the licensed organisation in-line with the trainthepainter quality manual TT/QA The protective coating applicator unit must be successfully completed by the student before they can attempt the abrasive blast cleaning operative or spray painter units.

8 Protective Coatings Application: UNIT 1 Objective: To understand the aims and objectives of the individual company, Health and Safety regulations and legislation. All companies must conduct an induction to new personnel. The company induction will vary from company to company and will differ globally. The company induction is a mandatory requirement. Additional site inductions may also be conducted for specific sites.this unit gives guidelines on what you may expect on a company Induction. Company Induction The form and layout of the induction will depend upon the company's activities and location of work. Induction will be conducted for all trades in the coatings industry and activities including: Site painters, Supervisors and Inspectors. Factory painters and other personnel. Offshore contractors and workers. Industrial workers. Cleaning contractors and workers. Miscellaneous workers. Copyright 2010 Fitz-Coatings Ltd - Page 2 - Student Name: Student ID Number: Trainer Name: Trainer Signature: Trainer ID Number: Revision 1 July 2012 (To be used in conjunction with Practical Assessment Guide) MPI Group, Peel House, Upper South View, Farnham, Surrey GU9 7JN, UK Tel: +44 (0) Fax: +44 (0) info@mpigroup.co.uk TRAINING AND ASSESSMENT NOTICE SUMMARY NAME OF STUDENT: DATE OF BIRTH: STUDENT ID: COMPANY ADDRESS: Protective Coating Applicator Passed Date Completed: 1. Health and Safety / / 2. Access, Plant and Equipment / / 3. Surface Preparation / / 4. Paint Types / / 5. Paint Application / / 6. Quality Control / / Abrasive Blast Cleaning Operative Passed N/A Date Completed: 1. Introduction / / 2. Health and Safety / / 3. Blast Media / / 4. Standards and Quality Control / / 5. Operational Procedures / / 6. Process Control / / Spray Painter Passed N/A Date Completed: 1. Introduction / / 2. Health and Safety / / 3. Paint Materials / / 4. Airless Safety Equipment / / 5. Conventional Air Spray / / Trainers Name: Trainers ID: Trainers Signature: TTP-010 trainthetrainer (taf01) Form application trainer Rev DATe AuThoR SignATuRe AppRoveD SignATuRe 0 B. Fitzsimons A. Deere 1 B. Fitzsimons A. Deere application Form (taf01) Date of application: location (Country): Company Contact: address: Company Company: address: name: Details Personal *Minimum level icorr level 2 no and expiry Date sspc PCi level 2 no and expiry Date Date expiry and no 3 level FRosio Date expiry and no 2 level nace Qualifications* other (state) yrs inspector yrs supervisor yrs Manager yrs What was your position during this period? yrs industry? coatings protective the in experience years many How experience the above candidate does /does not meet the requirement for the trainthetrainer course. only administration name: signature: Date: page 18 DOCUMENTATION HANDOUT NOTES All the training units have a full and comprehensive set of handout notes. These notes are automatically updated as the training is updated. The notes can be saved and printed. The handout notes are in PDF format. The handout notes can be printed in black and white or colour and can be given to the student during training. PROTECTIVE COATINGS APPLICATOR PRACTICAL ASSESSMENT RESULTS NOTICE SUMMARY SHEET ASSESSMENT RESULTS There are two assessment result forms used to document the practical units as segments in a tick box format. One is for the protective coatings application and the other is for the abrasive blast cleaning operative and spray painter. TRAINERS APPLICATION FORM (TAF01) The trainers for trainthepainter have to be approved and there are prerequisites for qualifications and experience. This form has to be completed by the company or trainer to gain approval before attending the train the trainer course. appendix e PRACTICAL Protective coatings application Practical assessment Guide ASSESSMENT GUIDES The practical assessment guides are available for the protective coatings application, the abrasive blast cleaning operative and the spray painter and assist the trainer in conducting the practical assessments. The documents are a step by step guide to ensure the practical assessments are consistence between all organisations. FINAL ASSESSMENT NOTICE There are two training and assessment notice summary sheets (1) Protective coating applicator (2) Abrasive blast cleaning operative and/or Spray Painter. These summary sheets should completed when the student has completed the theoretical and practical training. CONTRACT AGREEMENT FORM (CAF01) The contract agreement form is used when independent trainers or coating suppliers are used to conduct the practical assessment. The form acknowledges that the contractor accepts that they have safe equipment and insurance etc. KNOWLEDGE Knowledge RequiRements Protective Coatings Applicator Abrasive Blast Cleaning operator REQUIREMENTS Paint spraying operator The knowledge requirements document explains the objectives of every training unit and details the content of the theoretical and practical training units STUDENT THEORETICAL ASSESSMENT SHEET When the student completes a training unit they have to complete a questionnaire to demonstrate they understand the subject. There are two formats for this questionnaire. One is a multichoice answer sheet for online or a full printed question for offline. The online version allows 20 seconds per question. QUALITY ApplicAtor training programme Quality Manual tt/qa01 MANUAL (TT/QA01) The quality manual details the full administration of the training program and is used to audit the contractor on an annual basis. The licensed organisation (contractor, coating supplier or independent trainer) will have a copy of the latest revision of their quality manuals available together with relevant documents and records for the auditors review.

9 ABRASIVE BLAST CLEANING OPERATIVE The student will conduct a number of theoretical training sessions before conducting the practical training and assessments: Personal protective equipment Breathing air / helmet Types of abrasives Visual standards Environmental conditions Compressed air and air requirements Blast hose and associated equipment Types of nozzles Communications Equipment set up and testing Abrasive blast cleaning process Abrasive blast cleaning standards

10 COURSE INFORMATION Course duration This training programme is comprehensive; however, it is extremely flexible and can be delivered over a number of days, weeks or months to suit your organisation. All students must complete the protective coatings applicator course prior to conducting the abrasive blast cleaning and spray painting course. Protective Coatings Applicator Theoretical training 2-3 days Practical assessments 1-2 days Abrasive Blast Cleaning Operative Theoretical training 1 day Practical assessments 1 day Spray Painter Theoretical training 1 day Practical assessments 1 day The course duration is only a guide as this will depend upon the size of class, experience of students, language, availability of work shop etc. Handout notes All of the individual training units have a set of comprehensive handout notes which are regularly updated as the material is revised. The handout notes are colour PDF documents which can be downloaded, saved to computer or printed (colour or black and white). Documentation A number of documents are included within the training programme: Practical assessment guides for the protective coatings applicator, abrasive blast cleaning operative and spray painter Practical assessment results Knowledge requirements Theoretical questions and answers Certification Name Surname BRONZE CARD L1 Effective from 01/05/2013 Expiry 01/05/2015 Course Manager Name Surname SILVER CARD L2 Effective from 01/05/2013 Expiry 01/05/2015 Course Manager Name Surname GOLD CARD L3 Effective from 01/05/2013 Expiry 01/05/2015 Course Manager Bronze Card (level 1) - Protective Coatings Applicator Silver Card (level 2) - Protective Coatings Applicator and Abrasive Blast Cleaning Operative or Spray Painter Gold Card (level 3) - Protective Coatings Applicator and Abrasive Blast Cleaning Operative and Spray Painter Course delivery The course is delivered by both practical and theoretical classes with assessments conducted throughout the process. Training can be provided in bite size sections ensuring students fully understand each part of the programme. The trainthetrainer scheme is delivered at the premises of the contractor or an external paint shop / training facilities. A classroom is required for the theoretical training which is delivered via web or downloadable app when no internet access is available. The practical training and assessments must be conducted in a paint shop or work shop with the use of specifically designed test plates.

11 Tools Video and Animation Lists The user can search and select from all the videos and animations on the training programme Glossary A full glossary of coating terms with photographs and illustrations to support the text. Coating Defects Demonstrating common coating failures with photographs and text. Coating Breakdown Chart A visual percentage of scattered and localised coating breakdown. Computer generated charts give exact areas of coating breakdown unrelated to international standards Paint Calculation - Interactive items with the paint calculator such as volume solids or surface area allow an accurate calculation of paint volume required. Pre-surface Preparation - A photographic list of pre-surface preparation conditions is demonstrated illustrating weld spatter, arc strikes, grease, lamination, steel pitting, sharp edges, weld undercut, weld porosity and acceptable weld condition. Types of Abrasives - A photographic list of commonly used abrasives is demonstrated including iron silicate, sponge, olivine, garnet, calcium, silicate, chilled iron, iron shot, glass, walnut shell and plastic. Downloadable App version The Trainthepainter training programme can be uploaded directly onto your laptop or desktop allowing the trainer to access the training programme without internet access. Regular updates to videos, animations, text and training units are available and can be accessed by logging onto the site and clicking the updated button. This process is recommended monthly. Assessments To achieve a Trainthepainter certificate accredited by Lloyds Register students are required to attend a practical and theoretical assessment conducted by a qualified in house Trainthepainter assessor. Established in 1981 the MPI Group is a training, publishing and marketing company that has an impressive list of contacts and a detailed knowledge of the industry. MPI has worked in partnership with authoritative Institutes and Associations since 2003 to establish a series of professional training programmes. MPI Group Peel House, Upper South View Farnham, Surrey GU9 7JN, UK T +44 (0) F +44 (0) E trainthepainter@mpigroup.co.uk Jotun is one of the world s leading manufactuers of paints, coatings and powder coatings. We have 71 companies and 36 production facilities on all continents, and are represented in more than 90 countries with our network of agents, branch offices, distributors and sales offices around the world. Our operations cover development, production, marketing, R&D and sales of paints and coatings to protect and decorate surfaces in residential, shipping and industrial markets. Jotun is approved to run the Train The Painter course by MPI Group. Jotun A/S P.O.Box 2021, 3202 Sandefjord, Norway Stine Floberg Global Technical Training Manager Marine and Protective Coatings T M E stine.floberg@jotun.no Jotun.com

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