Rework Costs from Poor Surface Preparation

$10,000–$100,000 per project (rework due to aesthetic failure or premature coating degradation; client dissatisfaction; reputation damage; change orders and disputes) • $15,000–$75,000 per commercial building project (re-blasting at $80–150/sqft for 1,000–5,000 sqft façade + labor + material waste + schedule delay) • $20,000–$200,000 per warehouse project (rework coating and prep, facility downtime, material waste, potential secondary damage from moisture intrusion or structural rust)

Architectural firm specifies SSPC-SP10 in drawings; coating technician uses visual inspection against photographic standards; communication via email and site meetings; no objective surface profile or contamination measurement; aesthetic disputes resolved through rework after client complaint • Government agency requires certified third-party inspection and SSPC-PA2 surface profile gauge testing; technician logs prep stages in Excel or paper checklist; inspection reports filed as PDFs; disputes arise post-failure about whether gauge testing was accurate or representative; rework order issued based on failed sections identified retroactively • Manual visual inspection sheets, paper checklists, photograph documentation via phone, email chains confirming prep completion without objective verification of surface profile or cleanliness standard (SSPC-SP rating)