Case Studies
Selected project records demonstrating NCIS inspection methodology, quality governance, and documentation standards across heavy industrial, critical infrastructure, and water supply sectors.
Coating Failure Analysis and Repair Verification for Mission-Critical Industrial Equipment
North Coast Inspection Services (NCIS) was engaged by BEUMER Canada, a leading global manufacturer of bulk material handling systems, to conduct a comprehensive coating failure analysis and provide third-party quality assurance for the subsequent repair of critical conveyor equipment at Westshore Terminals in Delta, British Columbia. The project involved a multi-phase inspection scope on newly delivered bogie components that exhibited premature coating failure, requiring a rigorous, evidence-based approach to determine the failure mode and ensure the long-term integrity of the remedial coating work.
BEUMER Canada discovered significant coating adhesion failures on bogie components coated by an overseas supplier prior to delivery. The failures included delamination and loss of inter-coat adhesion across multiple components, posing a direct risk to the operational integrity and service life of the equipment. The original coating application lacked sufficient quality assurance records, making it essential to establish a clear, independent assessment of the failure mode before any remedial work could proceed. NCIS was initially introduced through a sub-contractor arrangement but was quickly elevated to a direct-to-client role, with BEUMER Canada granting NCIS full authority to lead the inspection and verification scope.
While DFT measurements at sampled locations were generally within the specified range and conforming under SSPC-PA 2, the inspection identified a systemic coating failure on multiple components attributable to loss of inter-coat adhesion. The inspection confirmed that adhesion failure is a performance-related defect independent of coating thickness, rendering the affected coatings unsuitable for service. Components inspected included nine drive motors, east and west boom gearbox motors, end stocks, and roller table accessories.
NCIS provided BEUMER Canada with the independent, evidence-based quality assurance needed to resolve a complex coating failure and ensure the long-term integrity of the repaired equipment. The project delivered objective verification of the failure mode, risk mitigation through witnessed repair execution, and a complete audit-ready inspection report package for asset management and supplier accountability purposes.
SSPC-PA 2, ISO 4624, ASTM D4541, Westshore PEP-JCC Coating Specification
A detailed visual assessment was conducted to document the initial condition of all affected components. This was followed by destructive pull-off adhesion testing in accordance with ASTM D4541 and ISO 4624 to quantify the bond strength between coating layers and at the primer-to-substrate interface. Dry film thickness (DFT) measurements were taken across all sampled locations and compared against the specified range of 125 to 175 micrometres per the Westshore PEP-JCC specification, with the specified system consisting of an Interzinc 52 primer with Interseal 670 HS intermediate and topcoat layers.
NCIS reviewed the repair proposal submitted by the designated repair contractor to ensure the proposed materials, surface preparation methods, and application procedures were compliant with the project specifications and applicable industry standards.
NCIS inspectors were deployed to witness and verify all critical stages of the repair process, including surface preparation, environmental condition monitoring, and wet film thickness (WFT) and dry film thickness (DFT) measurements throughout application.
NCIS conducted a final visual inspection and compiled a comprehensive inspection report package, providing a complete and traceable record of all inspection activities and findings.
Sustained Quality Assurance for Golden Ears Bridge Corrosion Repair Program
North Coast Inspection Services (NCIS) was retained by Civonic Engineering to provide comprehensive third-party quality assurance and inspection services for the Golden Ears Bridge Corrosion Repair Program. As one of Metro Vancouver's most critical transportation infrastructure assets, the Golden Ears Bridge requires a rigorous and proactive approach to corrosion protection to ensure its long-term structural integrity and public safety. NCIS deployed a team of AMPP-certified coatings inspectors to witness, verify, and document all critical phases of the corrosion repair program across both the east and west sides of the bridge, ensuring full compliance with the project's governing technical specification (WM-GEB-2024).
The Golden Ears Bridge is a 1-kilometre, six-lane extradosed cable-stayed bridge carrying tens of thousands of vehicles per day across the Fraser River. The corrosion repair program for such a high-profile, high-traffic public asset demands an exceptionally high level of quality control and documentation. Work was conducted at height in a challenging, fast-paced environment, requiring a highly disciplined and safety-conscious inspection team capable of maintaining consistent reporting standards across a multi-week, multi-inspector deployment. Civonic Engineering required a trusted, independent inspection partner to provide objective evidence that all surface preparation and coating application activities were performed in strict accordance with the project specifications.
NCIS's sustained inspection presence provided continuous, specification-compliant oversight of all surface preparation and coating activities. Quality issues were identified and resolved in real time, preventing non-conformances from progressing to acceptance stages. The multi-inspector deployment maintained consistent documentation standards across both east and west bridge repair operations throughout the full duration of the program.
NCIS's sustained inspection presence was instrumental in the successful delivery of the Golden Ears Bridge Corrosion Repair Program. The project delivered continuous, specification-compliant oversight of all surface preparation and coating activities, proactive identification and resolution of quality issues in real-time, and a comprehensive inspection report package providing a permanent, verifiable record for the client and asset owner.
SSPC-SP 10, SSPC-PA 2, ASTM D4541, VIS 1-2002, WM-GEB-2024
NCIS inspectors verified that abrasive blast cleaning of the steel cable stay components and associated structures achieved the specified SSPC-SP 10 (Near-White Metal) level of cleanliness. Abrasive media (GMA Garnet) was verified for cleanliness and freedom from contaminants. Chloride testing was performed on prepared surfaces prior to coating application.
Continuous monitoring of ambient conditions was maintained throughout all coating activities, including relative humidity, air temperature, surface temperature, and dew point. All readings were recorded and compared against the manufacturer's recommended application parameters to prevent application under adverse conditions.
NCIS delivered a comprehensive suite of daily inspection reports and quality reports, creating a complete and auditable record of all quality assurance activities. Over 60 individual inspection reports were filed over the course of the project, providing the client with a detailed, real-time record of the work as it progressed.
Douglas Road Main No. 2 — Critical Water Infrastructure Coatings QA
Metro Vancouver's Douglas Road Main No. 2 project was a critical regional infrastructure upgrade to ensure long-term water supply reliability for the Metro Vancouver region. The project involved constructing approximately 1.5 kilometres of 1,200 mm diameter steel watermain, including complex microtunnel crossings beneath Still Creek, major rail lines, and arterial roads. Given the high-consequence nature of the asset and the complexity of the installation, ensuring the long-term integrity of the protective coatings was a primary quality objective. North Coast Inspection Services (NCIS) was subcontracted by Stasuk Testing & Inspection to provide independent, third-party quality assurance oversight for all protective coatings activities, from initial surface preparation through to final acceptance.
The primary challenge was to provide end-to-end verification of the multi-layer protective coating system on a large-diameter steel watermain intended for decades of buried service. Any coating deficiencies, holidays, or failures in the shop or field could lead to premature corrosion, costly repairs, and significant service disruptions. The project required rigorous, evidence-based QA at every stage, including shop and field coordination across multiple work fronts, complex logistics through microtunnel sections, and verification against multiple governing documents including SSPC standards and Metro Vancouver's own detailed pipeline coating specifications.
NCIS's embedded QA role provided Metro Vancouver and Stasuk with confidence in the long-term durability of the critical watermain asset. Proactive identification and resolution of potential coating issues prevented costly rework and ensured a complete, unbroken chain of quality assurance across the entire coatings scope.
NCIS delivered full QA coverage across the entire coatings scope with a complete, unbroken chain of quality assurance. A comprehensive documentation package ensured full traceability of all coating activities and validated compliance with all governing specifications. Potential coating issues were proactively identified and resolved before they could lead to costly rework or future performance problems. The project was completed successfully and turned over to Metro Vancouver with the full integrity of the protective coating system validated and documented.
AMPP/NACE Level 3 QA Inspection, SSPC-SP Series (Surface Preparation), SSPC-PA 2 (DFT Measurement), ASTM D4541 (Adhesion Testing), Metro Vancouver Pipeline Coating Specifications
NCIS oversaw all coatings-related QA activities, from initial surface preparation and abrasive blast media verification to final cure validation and holiday testing.
The inspector conducted and witnessed a full suite of verification tests, including Dry Film Thickness (DFT) measurements (SSPC-PA 2), adhesion testing (ASTM D4541), and environmental condition monitoring (temperature, humidity, dew point).
NCIS liaised directly between the prime contractor (Stasuk), the asset owner (Metro Vancouver), and the coatings applicators to ensure clear communication, resolve non-conformances, and maintain project schedule.
All inspection activities, observations, and test results were documented in detailed daily inspection reports and formal Non-Conformance Reports (NCRs) where required, creating a complete audit trail of coating quality.
Confidentiality Notice: Client names, project references, and asset details are published with client knowledge and consent. Commercially sensitive information, proprietary specifications, and non-public project data have been excluded. All case study content is presented for the purpose of demonstrating NCIS inspection methodology and scope capability.
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