As a certified FROSIO Level III expert, I have repeatedly experienced exciting and new fields of application for specific inspections during my many years of professional experience. Here I share my experience, because the targeted use of FROSIO inspectors makes a valuable contribution to the longevity and efficiency of steel structures.
Inspection and non-destructive testing
Regular inspections and condition monitoring form the basis for quality assurance and maintenance management. The inspector's tasks can be summarized under "inspect, observe and report". Inspection ensures that work is performed in accordance with project specifications, procedures, and standards. The final report documents the findings and any discrepancies. StS provides condition monitoring and inspection of welding, surfacing and insulation work performed by specialists with professional experience and relevant certification such as FROSIO and NDT. A positive pressure habitat provides excellent working conditions for performing NDT in conjunction with hot work suction as welding operations often require NDT inspection upon completionTo address difficult access, StS offers NDT and FROSIO inspectors trained in industrial rope access.
1. Non-destructive testing methods
In addition to the already presented test methods HT Visual testing, VT Magnetic particle testing, MTEindentation testing, PT Eddy current testing, ET Ultrasonic testing, UT Radiography testing, there are further methods: RT Positive material identification PMI and hardness measurement HT.
2. PMI Positive material identification
Positive Material Identification (PMI) is used to analyze and identify material quality and alloy composition for quality and safety control. A rapid, non-destructive method of positive material identification is performed on a variety of components and assets and provides semi-quantitative chemical analysis. It is used for both material verification and identification. The method is used for quality control and safety compliance and is an essential part of managing the production and integrity of assets in many industries, including oil and gas, energy, chemical, pharmaceutical, nuclear, aerospace, and manufacturing. Positive material identification can prevent a potential product failure during manufacturing. In oil and gas, power generation and pharmaceutical companies, inspecting critical components and welds with PMI before and during operation can prevent failures and their costly consequences.
PMI can:
Ensure products/components are made from the correct alloy Find potentially mixed alloys Determine if the wrong material was used Ensure material is to the correct standard and specification (both customer and industry). Ensure welded components have used the correct filler material Positive material identification is performed using one of the following two techniques: X-ray fluorescence analyzer (XRF): this is the most commonly used method. Due to the portability of the handheld equipment, Intertek can perform PMI on-site at our customers' facilities. The instrument scans the metal material and identifies its key elements. However, it cannot detect carbon and some lighter elements and is not suitable for identifying pure carbon steel materials. Optical Emission Spectroscopy (OES): this method can detect almost all types of elements, including carbon and lighter elements as well as carbon steel. Although the instrument is not as portable as XRF analyzers, it can be transported to sites and used at high altitudes with appropriate lifting equipment. Intertek's experienced PMI inspectors can provide on-site results, followed by certification of the results in a written report. We also interpret and advise on the results. In addition, our response times ensure that we meet your production or inspection schedules. If further analysis is required, Intertek can provide the fully quantitative laboratory techniques to confirm the results. When you turn to us for positive material identification, you can count on fast, reliable service with accurate results that provide full quality assurance that your products or assets meet the required quality and safety standards in today's markets and industries.
3. HT Portable hardness test
Portable Hardness Testing (HT) is a non-destructive testing method used to determine the hardness value of a material. This method is used to test ferrous and non-ferrous metals and alloys, as well as selected non-metallic materials, welds and weld pads, weld heat affected zones (HAZ), castings and forgings, piping, stress relieved materials, machined parts, pressure vessels and structural steel. Damaged materials are inspected as part of a failure analysis for welds and to verify material conformance to: ASME Section IX NACE MR0175 / ISO 15156 requirements ADVANTAGES Rapid results and reporting to customer Field ready Highly portable tools can be used at most locations RESTRICTIONS Brinell hardness testing cannot be performed on thin material, in weld affected weld zones, and on surfaces where indentations are unacceptable, e. g. For example, finished surfaces MicroDur measurements require a surface that is polished to a near mirror finish The Equotip should only be used for parts with a thickness of ½ inch or more When electrical hardness testers are used, the temperature of the test material must not exceed approximately 200 ° F.
Enhancing Steel Structure Durability with FROSIO-Approved Surface Techniques
Industrial coating performance and life cycle are determined by various forms such as appropriate surface pretreatment methods, coating system selection, environment and cost.
FROSIO Specification Corrosion Protection: Long Lifespan for Your Steel Structure
Your FROSIO-certified inspector supports you in selecting an effective surface treatment. This ensures your structures have a long lifespan. Importantly, a precise FROSIO Specification Corrosion Protection is crucial for success.
All steel structures, whether small or large, face exposure to climate and corrosion. This exposure shortens their lifespan. However, the speed of degradation highly depends on the environment. For instance, a structure in an office differs greatly from one in a humid factory hall (e.g., for food preparation). Similarly, a rural hill site presents different challenges than a location directly by the sea.
Optimal Surface Treatment through FROSIO Expert Knowledge
Coatings and galvanization often protect steel surfaces from corrosion. Therefore, choosing the right paint system and managing the surface treatment process are vital. These steps are essential if your structure needs effective, long-term protection. Thus, coordinating for optimal surface treatment requirements, driven by FROSIO Specification Corrosion Protection, is always essential.
The Importance of Precise Requirements for Corrosion Protection
You must make various decisions about which requirements to specify. Insufficient requirements, for example, negatively impact the lifespan of structures. Conversely, overly demanding requirements can complicate the surface treatment unnecessarily. This also drives up costs. A FROSIO-certified (NS 476) inspector offers great value here; they clarify exactly which requirements you need to set for effective **corrosion protection**.
Key Areas for Specification by a FROSIO Expert
A FROSIO Expert helps you define these critical requirements, ensuring optimal **FROSIO Specification Corrosion Protection**. This includes, but is not limited to, the following points:
- Requirements regarding international standards like NORSOK M-501 and ISO 12944.
- Specific requirements for the surface quality of the steel.
- Acceptable material thickness loss before pre-treatment and surface treatment.
- Special requirements for the steel type (silicon content, wall thickness) to achieve desired zinc layer thickness through hot-dip galvanizing.
- The necessary degree of pre-treatment for welding and edges.
- Required purity after compressed air blasting (sandblasting) for good adhesion.
- Maximum permissible salt absorption on the steel surface.
- Determination of the corrosion category.
- Guidance on what type of paint system to choose.
- Assessment of whether the proposed surface treatment suits its purpose; analyzing strengths/weaknesses of the coating build-up.
- Required level of reporting and documentation from the surface finisher.
- Mandatory tests/inspections during the coating process and after the final coating.
- Who should conduct tests/inspections (e.g., self-control, client control, or third parties)?
- Definition of clear acceptance criteria.
- Special requirements concerning the coating’s appearance (e.g., ease of cleaning, color fastness, visibility of repairs).
For all these complex questions, your FROSIO-certified specialist and inspector provide full support. They assist you in defining the most optimal FROSIO Specification Corrosion Protection for your specific project. Furthermore, you can visit our page on Paint Inspections and Quality Control for more details on achieving robust **corrosion protection**.
A Precise FROSIO Specification Delivers the Expected Result
The surface finisher must perform their work exactly according to the specification. If a clear instruction is missing, they are entitled to do what they deem correct. However, good practices are not the same everywhere. Therefore, it’s crucial to include every detail in a comprehensive **FROSIO Specification Corrosion Protection**.
International Standards for Clear Corrosion Protection
For this reason, internationally recognized norms and standards for surface treatment were developed. These include DS / EN ISO 12944, DS / EN ISO 1461, and NORSOK M-501. By specifying according to these standards, the requirements for effective **corrosion protection** become unequivocally clear.
Consider this example: If P3 according to DS / EN ISO 8501-3 is specified, the surface finisher immediately knows welds must be perfectly smooth. Additionally, no weld beads should remain, and all edges must be rounded to a 2 mm radius. This level of detail removes guesswork.
The surface finisher also understands specific material requirements. For instance, if a paint system A5M.06 (per DS / EN ISO 12944) is specified, they know to apply a zinc primer layer. This primer uses epoxy, polyurethane, or ethyl silicate as a binder, with a dry film thickness of 40-80 µm. Subsequently, 3-4 layers of epoxy or polyurethane must follow, reaching a total dry film thickness of 320 µm. Thus, optimal surface treatment demands a precise definition of expectations.
A good, precise specification ensures your surface finisher knows exactly what to do. Consequently, your steel structure – whether it’s a wind turbine, a bridge, a tank, or something else entirely – receives optimal defense against corrosion. A FROSIO-certified inspector and specialist provides this optimal FROSIO Specification Corrosion Protection. It is firmly based on international standards. This also ensures that, in case of disputes, there is no doubt about your rightful claim.
Independent and Specialized Advice from FROSIO Experts for Corrosion Protection
Your specialist and FROSIO-certified inspector offer impartial, professional advice. They guide you on the best surface treatment choice. Furthermore, they help define the requirements for your surface finisher regarding execution and control. With a clear **FROSIO Specification Corrosion Protection**, you achieve durable and effective protection.