For CHS’s field coating team, missed DFTs, duplicate inspections, and rework were eating up budgets and morale. By switching to IntelliSpec’s Fireproofing & Coating AI module, they streamlined QA checks, digitized all forms, and empowered inspectors with AI-driven defect tagging — cutting rework nearly in half.
The Problem
Before IntelliSpec, coating inspections relied on paper logs and manual micrometer readings. With multiple crews and subcontractors working in shifts, CHS faced:
- Inconsistent DFT documentation
- Lack of traceability on coatings
- Delays in touch-up approvals
- Unnecessary rework when QA data went missing
“We had no visibility into who painted what, when, and whether it passed DFT — especially with third-party contractors rotating in and out,” said Ravi T., Coating Superintendent.
The Solution
CHS implemented IntelliSpec’s Fireproofing & Coating AI Module, using:
- Digital Coating Forms with offline syncing
- AI-driven image capture and DFT tagging
- GIS-based mapping of coated zones
- Live dashboard showing pass/fail rates, rework zones, and coating thickness logs
Inspectors used ruggedized tablets to capture before/after photos, run AI-assisted DFT checks, and escalate failed spots immediately to the touch-up team. Each coating record was auto-linked to asset tags and time-stamped.
The Impact
The first 6 weeks saw a dramatic shift:
- Field QA times dropped
- All parties operated from the same data
- Supervisors finally had traceable QA history by asset and crew
- Rework dropped 45% in 45 days
“For the first time, I knew exactly where the failures were — and why. That changed everything,” said Ravi.