Steel Coating Inspection Course

Lesson 1 • Corrosion Types on Structural Steel

Identifies and distinguishes uniform, pitting, crevice, and stress corrosion forms. Builds visual recognition skills essential for field inspection.

Lesson 2 • Steel Metallurgy Essentials

Covers steel composition, microstructure, and mechanical properties critical to coating adhesion. Connects material science fundamentals to inspection decision-making.

Lesson 3 • Protective Coating Functions and Types

Introduces barrier, inhibitive, and sacrificial coating mechanisms and their applications. Frames the role of coatings within a complete corrosion protection strategy.

Lesson 4 • Regulatory and Standards Framework

Surveys international coating and inspection standards, their structure, and applicability. Equips students to locate and apply relevant requirements on any project.

Lesson 1 • Contamination Documentation and Reporting

Structures field data collection, photographic evidence, and written reports for contamination findings. Accurate records support quality assurance and dispute resolution.

Lesson 2 • Oil and Grease Detection

Covers visual, UV fluorescence, and solvent wipe methods for hydrocarbon contamination detection. Ensures students can confirm surface cleanliness before abrasive operations.

Lesson 3 • Soluble Salt Testing Methods

Teaches conductimetric, Bresle patch, and ion-specific test procedures for salt quantification. Accurate salt measurement directly determines surface preparation requirements.

Lesson 4 • Existing Coating Condition Assessment

Applies adhesion pull-off tests, dry film thickness gauging, and visual rating scales to existing coatings. Findings drive the decision between overcoating and full removal.

Lesson 1 • Mechanical and Hand Tool Preparation

Demonstrates needle gun, angle grinder, wire brush, and hand scraper techniques for localised preparation. Appropriate for spot repairs and areas inaccessible to blast equipment.

Lesson 2 • Wet Abrasive and Waterjetting Methods

Addresses wet abrasive blasting, ultra-high-pressure waterjetting, and flash rust inhibitor use. Expands preparation options for environments where dry blasting is restricted.

Lesson 3 • Surface Profile Measurement

Teaches replica tape, digital profilometer, and comparator methods for anchor profile quantification. Profile depth directly affects coating adhesion and specified film thickness.

Lesson 4 • Abrasive Blast Cleaning Techniques

Covers abrasive types, blast equipment, nozzle selection, and operational parameters for dry blasting. Students achieve specified cleanliness and anchor profile consistently.

Lesson 5 • International Preparation Grade Standards

Explains Sa, St, and Wa preparation grade systems and their visual reference comparators. Provides the common language used in specifications and inspection reports.

Lesson 1 • Primer, Intermediate, and Topcoat Roles

Defines the functional contribution of each coat layer to adhesion, barrier protection, and UV resistance. System layer understanding prevents specification errors and application defects.

Lesson 2 • Coating System Compatibility and Testing

Evaluates intercoat adhesion, overcoating windows, and accelerated test data for system validation. Compatibility verification prevents delamination and warranty disputes.

Lesson 3 • Coating Specification Writing

Structures a complete coating specification including surface preparation, product data, and inspection hold points. A well-written specification is the contractual and quality baseline for every project.

Lesson 4 • Coating Chemistry and Binder Types

Examines epoxy, polyurethane, alkyd, zinc silicate, and thermal spray binder chemistries and cure mechanisms. Chemistry knowledge underpins correct application and troubleshooting decisions.

Lesson 1 • Airless Spray Application

Covers airless pump setup, tip selection, pressure settings, and spray technique for structural steel. Airless spray is the primary production method for large structural coating projects.

Lesson 2 • Conventional and HVLP Spray Methods

Explains conventional air spray and HVLP equipment for detail work, touch-up, and complex geometry. These methods complement airless spray where transfer efficiency and control are priorities.

Lesson 3 • Application Environmental Controls

Addresses temperature, relative humidity, dew point, and substrate temperature requirements for coating application. Environmental control prevents moisture-related adhesion failures and cure defects.

Lesson 4 • Wet and Dry Film Thickness Measurement

Demonstrates wet film comb gauges and magnetic dry film gauges for thickness verification during and after application. Thickness compliance is the primary quantitative acceptance criterion.

Lesson 1 • Pre-Application Inspection Checks

Covers substrate verification, ambient condition checks, and material confirmation before coating begins. Pre-application inspection prevents defects that are costly to correct after application.

Lesson 2 • Inspector Roles and Inspection Planning

Defines inspector authority, independence, and pre-job inspection planning activities. Structured planning ensures all hold points and witness points are covered without production delays.

Lesson 3 • Coating Defect Identification and Causes

Identifies runs, sags, pinholes, blistering, delamination, and mud cracking with their root causes. Defect diagnosis enables targeted corrective action and prevents recurrence.

Lesson 4 • Inspection Records and Non-Conformance

Structures inspection report formats, non-conformance report issuance, and corrective action tracking. Complete records protect all parties and demonstrate regulatory compliance.

Lesson 5 • Adhesion Testing and Acceptance

Performs cross-cut, X-cut, and pull-off adhesion tests and interprets results against specification limits. Adhesion testing provides quantitative confirmation of coating system integrity.

Lesson 1 • Structural Steel Condition Survey Methods

Covers visual survey, thickness measurement, and corrosion mapping techniques for in-service structures. Systematic surveys generate the data needed to define refurbishment scope accurately.

Lesson 2 • Remaining Coating Life Assessment

Evaluates existing coating condition using standardised rust, blistering, and adhesion rating scales. Remaining life estimates determine whether maintenance painting or full removal is warranted.

Lesson 3 • Work Scope Definition and Sequencing

Translates condition assessment findings into a detailed work scope with preparation grades, coating systems, and area quantities. A precise scope prevents scope creep and enables accurate tendering.

Lesson 4 • Containment and Environmental Controls

Designs containment systems for dust, abrasive, and coating overspray control during in-service refurbishment. Containment protects the public, environment, and adjacent operations.

Lesson 1 • Root Cause Analysis for Coating Failures

Applies structured root cause analysis tools to investigate premature coating failures on completed projects. Systematic analysis prevents recurrence and supports warranty and insurance claims.

Lesson 2 • Continuous Improvement and Lessons Learned

Establishes processes for capturing lessons learned, updating specifications, and improving inspection procedures. Continuous improvement raises quality outcomes across successive projects.

Lesson 3 • Third-Party Inspection and Witness Testing

Defines the role, authority, and reporting obligations of independent third-party inspectors. Third-party inspection provides objective verification for owners, insurers, and regulators.

Lesson 4 • Quality Management System Integration

Aligns coating inspection activities with project quality plans, ITPs, and management system requirements. Integration ensures inspection outputs feed formal quality assurance processes.