Consolidated Acceptance Criteria Tables
The following tables consolidate acceptance limits from the referenced ASTM standards and typical industry specifications. These are reference values only — always verify against the applicable project specification, coating manufacturer requirement, and current ASTM standard revision.
Contamination Acceptance Criteria
| Parameter | ASTM Method | Atmospheric Service | Immersion / Buried | Offshore / CUI |
|---|---|---|---|---|
| Conductivity | D4940 | ≤ 1000 µS/cm | ≤ 500 µS/cm | ≤ 300 µS/cm |
| Chloride ion (Cl⁻) | D512 | ≤ 25 mg/L | ≤ 10 mg/L | ≤ 5 mg/L |
| Sulfate ion (SO₄²⁻) | D516 | ≤ 50 mg/L | ≤ 25 mg/L | ≤ 10 mg/L |
| Visible contaminants | D7393 | Zero Tolerance — All Service Categories | ||
| Oil/water in air | D4285 | Zero Tolerance — No Staining on Blotter | ||
| Moisture content | D4643 | ≤ 0.5% (mineral) ≤ 0.2% (metallic) |
≤ 0.2% | ≤ 0.1% |
Particle Size Acceptance Criteria — Steel Abrasives (SAE J444)
| SAE Designation | Nominal Size | % Retained on Coarser Sieve | % Retained on Nominal Sieve | Max % Passing Finer Sieve |
|---|---|---|---|---|
| G-10 (Steel Grit) | No. 10 (2.00 mm) | Min 80% on No. 7 | Min 85% on No. 10 | Max 10% passing No. 18 |
| G-16 | No. 16 (1.18 mm) | Min 80% on No. 12 | Min 85% on No. 16 | Max 10% passing No. 25 |
| G-25 | No. 25 (0.71 mm) | Min 80% on No. 18 | Min 85% on No. 25 | Max 10% passing No. 40 |
| S-330 (Steel Shot) | No. 18 (1.00 mm) | Min 80% on No. 16 | Min 85% on No. 18 | Max 10% passing No. 35 |
| S-230 | No. 25 (0.71 mm) | Min 80% on No. 18 | Min 85% on No. 25 | Max 10% passing No. 50 |
| S-110 | No. 40 (0.425 mm) | Min 80% on No. 35 | Min 85% on No. 40 | Max 10% passing No. 80 |
Surface Profile Acceptance Criteria
| Coating System | Profile Range (µm) | Profile Range (mil) | Measurement Method |
|---|---|---|---|
| Zinc-rich primer (inorganic) | 40–75 µm | 1.5–3.0 mil | D4417 Method B or C |
| Epoxy coating systems | 37–75 µm | 1.5–3.0 mil | D4417 Method B or C |
| High-build epoxy / phenolic | 50–100 µm | 2.0–4.0 mil | D4417 Method B or C |
| Thermal spray zinc/aluminium | 75–115 µm | 3.0–4.5 mil | D4417 Method C preferred |
| Polyurethane (thin-film) | 25–50 µm | 1.0–2.0 mil | D4417 Method B or C |
| Pipeline FBE coating | 37–75 µm | 1.5–3.0 mil | D4417 Method B or C |
Abrasive Blast Inspection Checklist
The following checklists are based on ASTM D3276 (Guide for Painting Inspectors) and SSPC-PA 1 inspection hold points. They are intended for use by QA/QC inspectors and third-party inspection personnel.
📋 PRE-JOB ABRASIVE ACCEPTANCE CHECKLIST
⚙️ IN-PROCESS BLAST INSPECTION CHECKLIST
✅ POST-BLAST ACCEPTANCE CHECKLIST
Abrasive Test Report Template
The following format is the recommended minimum test report structure for abrasive lot qualification. It can be adapted to laboratory information management systems (LIMS) or used as a paper-based form.
Date: ____________
SECTION 1 — SAMPLE IDENTIFICATION
SECTION 2 — TEST RESULTS
| Test Parameter | ASTM Method | Result | Units | Specification Limit | PASS / FAIL |
|---|---|---|---|---|---|
| Visual inspection | D7393 | _______ | — | No contamination | ___ |
| DI water blank conductivity | D4940 | _______ | µS/cm | ≤ 1.0 µS/cm | ___ |
| Abrasive conductivity (corrected) | D4940 | _______ | µS/cm | ≤ _____ µS/cm | ___ |
| Chloride ion (if required) | D512 | _______ | mg/L | ≤ _____ mg/L | ___ |
| Sulfate ion (if required) | D516 | _______ | mg/L | ≤ _____ mg/L | ___ |
| Moisture content | D4643 | _______ | % mass | ≤ _____ % | ___ |
| % Passing No. ___ | C136 / E11 | _______ | % passing | ___ | ___ |
| % Passing No. ___ | C136 / E11 | _______ | % passing | ___ | ___ |
| % Passing No. ___ | C136 / E11 | _______ | % passing | ___ | ___ |
| Bulk density | C29 | _______ | kg/m³ | ___ | ___ |
SECTION 3 — EQUIPMENT USED
SECTION 4 — DISPOSITION
Certificate of Analysis (CoA) Review Procedure
Every abrasive delivery must be accompanied by a manufacturer's Certificate of Analysis (CoA). The CoA must be reviewed before any independent testing is conducted and before any material is accepted or placed into storage.
CoA Minimum Required Information
Administrative Fields
- Manufacturer name and address
- Product name and grade/designation
- Lot/batch number
- Production date
- Test date
- ASTM standard references
- Authorised signatory + date
Technical Data Fields
- Conductivity (µS/cm) — ASTM D4940
- Particle size distribution — ASTM E11
- Hardness (Vickers or Mohs)
- Bulk density (kg/m³)
- Specific gravity
- Moisture content (%)
- Chloride/Sulfate (if applicable)
Non-Conformance Handling
A non-conformance (NC) exists when any abrasive test result falls outside the specified acceptance criterion, when CoA data is missing or unverifiable, or when visual inspection identifies prohibited contamination.
Immediate Segregation
Physically segregate and label the non-conforming material: "HOLD — DO NOT USE — NC REF: [NCR Number]". Prevent any non-conforming abrasive from entering the blast process. Document location, quantity, and container IDs.
Non-Conformance Report (NCR)
Raise a formal NCR within 24 hours. Record: NC description, affected material quantity and lot, test method and result, applicable specification limit, date/time discovered, inspector details. Assign a unique NCR number. Notify the coating/blast contractor and owner representative per project NCR procedure.
Disposition Decision
Possible dispositions: (a) Reject and return to supplier; (b) Re-test additional increments from lot — if 3 additional samples all pass, conditional lot acceptance may be considered; (c) Use As Is — only if engineering deviation is approved in writing by the owner's representative and coating manufacturer; (d) Remediation — for moisture exceedance only, dry abrasive and retest before use.
Corrective Action & Closeout
Determine root cause. Issue corrective action to supplier if systemic issue is identified. Update approved supplier register. Close NCR only after disposition is completed and verified. Retain NCR records for minimum 5 years or project record retention period.
QA Program Framework
An effective abrasive QA program integrates manufacturer qualification, incoming lot testing, in-process monitoring, and records management into a documented system aligned with ISO 9001 principles.
| QA Element | Requirement | Documentation |
|---|---|---|
| Approved Supplier Register | Pre-qualified suppliers only; annual review | Supplier evaluation records |
| Incoming Lot Testing | 100% lot CoA review; independent testing per frequency plan | Test reports; CoA file |
| Test Method Procedures | Written SOPs for each ASTM method used | SOP index + procedures |
| Equipment Calibration | Calibration program per schedule; NIST-traceable | Calibration register + certificates |
| Sampling Plan | Written plan: frequency, method, sample size, responsibility | Sampling Plan document |
| Laboratory Personnel Competency | Training records; demonstrated test competency (witnessed test) | Training matrix + records |
| NCR System | Documented NCR procedure; 100% raise on NC events | NCR log + records |
| Records Management | Traceable, retrievable records; minimum 5-year retention | Record retention procedure |
| Internal Audits | Annual audit of abrasive QA activities | Audit schedule + reports |
| Management Review | Annual review of QA program effectiveness | Management review minutes |
Quick Reference Resources
Acceptance Criteria
Consolidated limits for contamination, gradation, and physical properties.
View TablesInspection Checklists
Pre-job, in-process, and post-blast inspection checklists for field use.
View ChecklistsTest Report Template
Standardized abrasive lot test report format for all ASTM tests.
View TemplateContamination Testing
D4940 conductivity, D512/D516 ion analysis, D4285 air quality procedures.
View Procedures