How CHS Slashed Coating Rework by 45% Using intelliSPEC’s AI-Driven Workflow

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 Real Problem Isn’t Paint — It’s Process

At Gulf Integrity Services (GIS), a contractor managing coating scopes for a major petrochemical facility in Louisiana, this problem came to a head during a recent outage. Inspectors were documenting DFTs (Dry Film Thickness) on paper logs, contractors were rotating across shifts, and the superintendent had no real-time view into failures, touch-ups, or compliance.

“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 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

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.”

Key Results & Achievements

Measurable outcomes and achievements demonstrating the transformative impact and value realized from the intelliSPEC implementation.

Efficiency Gains

Achieved a 45% reduction in coating rework within just 6 weeks of implementing the solution.

Data Integrity

Ensured 100% digital QA log coverage, eliminating manual errors and data loss across all sites.

Inspection Speed

Enabled 30% faster DFT validation, significantly speeding up quality checks and sign-offs.

Full Traceability

Provided full traceability for every job by zone, crew, and asset, meeting strict audit requirements.

Platform Adoption

Facilitated easy adoption across the entire ecosystem: “One platform for everyone — even third-party contractors.”

Operational Improvement

Streamlining inspection workflows to drive operational excellence across all facility maintenance cycles.