Voluntary Certification Program for Fusion-Bonded Epoxy Coating Applicator Plants. Quality Coating = Corrosion Protection

Transcription

1 Voluntary Certification Program for Fusion-Bonded Epoxy Coating Applicator Plants 12 th Edition, 2012 Quality Coating = Corrosion Protection 2012 Concrete Reinforcing Steel Institute 933 N. Plum Grove Road Schaumburg, IL Phone: (847) Fax: (847) /31/ Official Plant Cert Manual 12 Edition January docx

2 FOREWORD The Concrete Reinforcing Steel Institute's (CRSI's) Voluntary Fusion-Bonded Epoxy Coating Applicator Plant Certification Program covers the production of epoxy-coated steel reinforcing bars and epoxy-coated custom products. The principles and requirements set forth in this Manual are intended to assess a Plant's ability to consistently produce fusion-bonded epoxy-coated steel reinforcing bars to the specifications described in this Manual. The Certification Program also provides Plant management with a tool to monitor and improve the quality of production, and provides purchasers, and specifiers with a basis for assessing the capabilities of the epoxy coating Plant. This Manual consists of four parts. Part I details the administrative requirements of the Certification Program. Part II contains the technical requirements that form the basis for certification and lists the Plant Quality Control Procedures and Inspection Agency Guidelines for straight bar lines. Part III consists of appendices that include a list of technical references, test methods, sample forms, a list of vendors for epoxy coating related supplies, glossary, and optional Fabrication Procedures for the fabrication of epoxy coated steel reinforcing bars. Part IV consists of the technical basis for certification of custom coated products. The Certification Program represents the current state-of-the art and consensus of the epoxy-coated reinforcing steel industry. During the on-going development of this Certification Program, representatives from industry and specifying agencies were given the opportunity to participate in its development. As new research is carried out and continued experience is gained, the technical criteria, which are the foundation of the Certification Program, will be refined and updated. The requirements of the Certification Program will be modified as necessary to reflect applicable standards, research, and changes in technology. Development of the Certification Program was initiated by a task group of the CRSI Epoxy Coating Technical Committee in This task group consisted of industry and government volunteers who worked diligently to develop the Certification Program. Our sincere gratitude is expressed to those who have contributed to the development of the Certification Program. Currently, the Certification Program is overseen by the CRSI Committee on Epoxy Coating Plant Certification whose members are: Mike Barrett, Chairman Tom Greenfield, Vice Chairman Marcelo Acuña, Jr. Marshall Bonds Peter Fosnough Mark Jacobsen Robert Marinella David McDonald James Reimenschneider John P. Simmet Jack Vanier Kuru Varughese W. Brice Wager Stephen Witts Paul Virmani Danielle Kleinhans (Secretary) 1/31/ Official Plant Cert Manual 12 Edition January docx

3 Table of Contents Part I Certification Program Administration Chapter 1 Introduction 1.1 Purpose and Description 1.2 Scope 1.3 Eligibility 1.4 Inspection and Certification Chapter 2 Certification Program Administration 2.1 Certification Program Administrator 2.2 CRSI Epoxy Coating Plant Certification Committee 2.3 Inspection Agency 2.4 Record Keeping Chapter 3 Application for Certification 3.1 Fees 3.2 Conditions 3.3 Effective Certification Date Chapter 4 Plant Inspections 4.1 Scheduling 4.2 Subsequent Inspections 4.3 Plant Liaison 4.4 Access to Information 4.5 Inspection Agency Duties Chapter 5 Inspection Grading 5.1 Grading Schedule 5.2 Grade Computation 5.3 Passing Grade 5.4 Inspection Reports 5.5 Roster of Certified Plants 5.6 Automatic Grade Deduction for Failure to Address Deficiencies Chapter 6 Disputes Process 6.1 Introduction 6.2 Clarification/Mediation 6.3 Appeal by Arbitration 6.4 Rules for Appeal by Arbitration Chapter 7 Confidentiality 7.1 Limitation on Public Release of Information 7.2 Inspection Agency Chapter 8 Change of Conditions Notification to Certification Program Administrator Chapter 9 Evidence of Non-Compliance Chapter 10 Notification 1/31/ Official Plant Cert Manual 12 Edition January docx

4 Part II Plant Quality Capability Criteria for Straight Bar Lines Chapter T1 Plant s Quality Control Quality Policy and Procedures T1.1 Description T1.2 Plant Quality Procedure(s) T1.3 Inspection Agency Guidelines Chapter T2 Surface Condition of Uncoated Steel Reinforcing Bars T2.1 Contaminants T2.2 Surface Defects Chapter T3 Surface Preparation T3.1 Abrasive Blast Cleaning (Critical Quality Criterion) T3.2 Anchor Profile (Critical Quality Criterion) T3.3 Abrasive Contamination and Gradation Chapter T4 Heating T4.1 Bar Surface Temperature Chapter T5 Epoxy Powder T5.1 Storage and Handling of Epoxy Powder Chapter T6 Epoxy Powder Application T6.1 Cleaning/Coating Application Interval T6.2 Epoxy Powder Application T6.3 Air Supply Chapter T7 Curing T7.1 Time-to-Support T7.2 Time-to-Cure Chapter T8 Continuity of Coating T8.1 Holiday Monitoring (Critical Quality Criterion) Chapter T9 Coating Thickness T9.1 Coating Thickness Monitoring (Critical Quality Criterion) Chapter T10 Assessment of Epoxy Coating T10.1 Coating Flexibility Monitoring (Critical Quality Criterion) T10.2 Cathodic Disbondment Chapter T11 Handling and Storage of Epoxy-Coated Reinforcing Bars T11.1 Handling and Storage T11.2 Outdoor Storage T11.3 Bar Identification and Rejected Material 1/31/ Official Plant Cert Manual 12 Edition January docx

5 Part III Appendices Appendix A1 Related Standards and References A1.1 ASTM Standards and References A1.2 SSPC Standards and References A1.3 NACE Standards and References A1.4 CRSI Publications Appendix A2 Test Methods Test Method 1: (TM-1) Backside Contamination Tape Test Test Method 2: (TM-2) Visual Comparison Against Cleanliness Standards Test Method 3A: (TM-3A) Detection of Chlorides - Chloride Test Paper Test Method 3B: (TM-3B) Detection of Chlorides Using Quantab Test Method 4: (TM-4) Copper Sulfate Test Test Method 5: (TM-5) Electronic Stylus (Profilometer) Measurements of Profile Test Method 6: (TM-6) Surface Profile Measurements Using Replica Tape Test Method 7: (TM-7) Sieve Analysis of Blast Abrasive Test Method 8: (TM-8) Oil Contamination Test Test Method 9: (TM-9) Temperature Check Using Non-Sulfurous, Temperature-Sensitive Crayons Test Method 10: (TM-10) Discontinuity (Holiday) Testing Test Method 11: (TM-11) Coating Film Thickness Measurement Test Method 12: (TM-12) Coating Flexibility Test for Flexible Epoxy-Coated Steel Reinforcing Bars Test Method 13: (TM-13) Cathodic Disbondment Test Test Method 14: (TM-14) Statistical Quality Control for Coating Continuity Test Method 15: (TM-15) Statistical Quality Control for Coating Thickness Appendix A3 Grading Schedule Appendix A4 Sample Inspector Grade Commentary Form Appendix A5 Guideline for Mediation Form Appendix A6 Sample Plant Inspection Form Appendix A7 Sources of Equipment and Supplies Appendix A8 Visual Standards A 8.1 Backside Contamination A 8.2 Chloride A 8.3 Copper Sulfate Appendix A9 Glossary Appendix F Optional Fabrication Quality Procedures for CRSI Certified Epoxy-Coating Plants Introduction Chapter F1: Fabrication Policy and Quality Control Procedures for Epoxy - Coated Steel Reinforcing Bars Chapter F2: Epoxy - Coating Patching Materials Chapter F3: Handling and Storage Prior to Fabrication of Epoxy - Coated Steel Reinforcing Bars Chapter F4: Bending and Shearing of Epoxy - Coated Steel Reinforcing Bars Chapter F5: Storage and Handling of Epoxy - Coated Steel Reinforcing Bars After Fabrication Chapter F6: Epoxy - Coated Bar Identification and Rejected Epoxy Coated Steel Reinforcing Bar Chapter F7: Repair of Damaged Epoxy Chapter F8: Outdoor Storage of Epoxy - Coated Steel Reinforcing Bars 1/31/ Official Plant Cert Manual 12 Edition January docx

6 Part IV - Plant Quality Capability Criteria for Custom Coated Products Chapter TC1 Quality Policy and Procedures Chapter TC2 Surface Condition of Custom Products to be Coated TC2.1 Contaminants TC2.2 Surface Defects Chapter TC3 Surface Preparation of Custom Coated Products TC3.1 Abrasive Blast Cleaning (Critical Quality Criterion) TC3.2 Anchor Profile (Critical Quality Criterion) TC3.3 Abrasive Contamination and Gradation Chapter TC4 Heating of Custom Coated Products TC4.1 Custom Product Surface Temperature Chapter TC5 Epoxy Powder for Custom Coated Products TC5.1 Storage and Handling of Epoxy Powder Chapter TC6 Epoxy Powder Application for Custom Coated Products TC6.1 Cleaning/Coating Application Interval TC6.2 Epoxy Powder Application TC6.3 Air Supply Chapter TC7 Curing of Epoxy on Custom Coated Products TC7.1 Time-to-Cure Chapter TC8 Continuity of Coating Custom Coated Products TC8.1 Holiday Monitoring (Critical Quality Criterion) Chapter TC9 Coating Thickness for Custom Coated Products TC9.1 Coating Thickness Monitoring (Critical Quality Criterion) Chapter TC10 Coating TC10.1 Coating Flexibility Monitoring (Critical Quality Criterion) TC10.2 Cathodic Disbondment Chapter TC11 Handling and Storage of Epoxy-Coated Custom Product TC11.1 Handling TC11.2 Outdoor Storage TC11.3 Custom Product Identification and Rejected Material Custom Product Test Methods for Custom Coated Products Test Method 1: (TMC-1) Backside Contamination Tape Test Test Method 2: (TMC-2) Visual Comparison Against Cleanliness Standards Test Method 3A: (TMC-3A) Detection of Chlorides - Chloride Test Paper Test Method 3B: (TMC-3B) Detection of Chlorides Using Quantab Test Method 4: (TMC-4) Copper Sulfate Test Test Method 5: (TMC-5) Electronic Stylus (Profilometer) Measurements of Profile Test Method 6: (TMC-6) Surface Profile Measurements Using Replica Tape Test Method 7: (TMC-7) Sieve Analysis of Blast Abrasive Test Method 8: (TMC-8) Oil Contamination Test Test Method 9: (TMC-9) Temperature Check Using Non-Sulfurous, Temperature-Sensitive Crayons Test Method 10: (TMC-10) Discontinuity (Holiday) Testing Test Method 11: (TMC-11) Coating Film Thickness Measurement Test Method 12: (TMC-12) Coating Flexibility Test for Epoxy-Coated Steel Custom Product 1/31/ Official Plant Cert Manual 12 Edition January docx