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Protective Coatings: Inspection, Maintenance and Repair

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 Course Overview

This 5-day training course thoroughly and systematically covers every aspect of coatings application and inspection techniques, maintenance and repair procedures. Coatings selection, specifications, applications and relevant industry standards for surface preparations of various substrates such as steel, galvanized steel, stainless steel, copper, and aluminum are also discussed in depth. The effect of cathodic protection on the performance of coatings is also covered in detail. This coatings short course trains the participants with the knowledge and skills required for effective coatings inspection, maintenance and repair of both organic coatings (or paints) and metallic coatings such as hot-dip galvanizing and metallic spray (or metallization).

This coatings inspection course can be taken as in-house training course, course-on-demand, online course and distance learning course worldwide. It can also be customized to meet the specific needs of your organization.


Course Outline |Who Should Attend |Registration |In-House |On-Demand |Online Courses |PPT Slides+Testbank |Course List

 Course Outline
  1. The Role of a Coating Inspector

    1.1 The Basic Requirements of A Coating Inspector
    1.2 Types of Coatings Inspectors
    1.3 The Roles of Coating Inspectors
    1.4 Accountability of A Coating Inspector
    1.5 Coatings Inspection Requirements
    1.6 Case studies on coatings-related disputes resulting arbitrations and litigations

  2. Corrosion Concepts Relevant to Coatings

    2.1 Definition and classification of corrosion
    2.2 Various forms of corrosion and its control
    2.3 The need for coatings
    2.4 Major factors influencing corrosion and the durability of coatings

  3. BS & ISO Classification of Corrosive Environments

    3.1 British standard (BS) and International standard (ISO)
    3.2 The duration of corrosion: Time of wetness (ToW)
    3.3 Coatings for protection of corrosion in atmospheres
    3.4 Coatings for protection of corrosion in water and soil
    3.5 Coatings for corrosion protection: special situations and special stresses

  4. Characteristics of Coatings

    4.1 Physical barrier and special functions of coatings
    4.2 Essential coating properties
    4.3 Inhibitive primers
    4.4 Importance of moisture vapor transfer rate (M.V.T.) of various coatings
    4.5 MVT and coating blistering
    4.6 Osmosis and osmotic blistering: causes and prevention
    4.7 Electroendosmosis: causes and prevention


  5. Fundamentals of Coatings

    5.1 ISO standard: definitions of coatings, paints and lining
    5.2 Basic components of coatings
    5.3 Functions of pigment, binder and solvent in a coating system
    5.4 General functions of each coat: primer, intermediate coat and top coat
          Question: Is a single coat better than a multi-coat at the same dry-film-thickness?
    5.5 Mechanisms of protection
    5.6 Common coatings and their compositions

  6. The Protective Coating System

    6.1 ISO standard definition of terms: pot life, shelf life, DFT, NDFT, VOC, tie coat, stripe coat etc.
    6.2 Different types of paint
    6.3 ISO paint durability classification
    6.4 ISO durability vs guarantee time
    6.5 Shop and site application: advantages and disadvantages

  7. Corrosion Resistant Organic Coatings

    7.1 Protective coatings classification
    7.2 Mechanisms of curing
    7.3 Natural-air oxidizing coatings
    7.4 Synthetic-air oxidizing coatings
    7.5 Solvent dry lacquers
    7.6 Coreactive coatings
    7.7 Emulsion type coatings
    7.8 Heat-condensing coatings
    7.9 100% solid coatings

  8. Corrosion Resistant Zinc Coatings: zinc-rich coatings vs hot-dip galvanizing

    8.1 Zinc and its sacrificial protection to steel substrate
    8.2 Organic zinc-rich coatings and its properties
    8.3 Inorganic zinc-rich coatings and its properties
    8.4 Organic zinc-rich vs. Inorganic zinc-rich coatings
    8.5 Hot-dip galvanizing and hot-dip galvanized zinc coatings
    8.6 Zinc-rich paint vs. hot-dip galvanizing: When and Where to use them

  9. Designing for Coatings

    9.1 Basic design criteria for corrosion protection purposes
    9.2 Accessibility, Treatment of gaps, Precautions to prevent retention of deposits and water
    9.3 Edges, Welding surface imperfections, Bolted connections, Box members and hollow components
    9.4 Notches, Stiffeners, Prevention of galvanic corrosion, Handling, transport and erection

  10. Effect of Substrate on Coating Life

    10.1 The Importance of Surface Cleanliness: "visually clean" vs "chemically clean"
    10.2 The Substrate Effect & Coating Life
    10.3 Types of Substrates: Steel,  Galvanized steel, Stainless steel, Aluminium, Wood & Concrete etc.
    10.4 Millscale and its effect on a coating's performance
    10.5 Surface contaminants: moisture contamination
    Surface contaminants: water-soluble salts and osmotic blistering
    10.7 ISO standard on acceptable chloride levels on sandblasted surfaces
    10.8 Surface contaminants: oil and grease
    10.9 Other surface contaminants: fungal/algal growth and efflorescence

  11. Importance of Surface Preparation

    11.1 BS, ISO, SIS, NACE and SSPC Standards on Surface Preparation
    11.2 Hand Tool Cleaning
    11.3 Mechanical or Power Tool Cleaning
    11.4 Solvent Cleaning/Degreasing Acid Pickling
    11.5 Abrasive Blast Cleaning
    11.6 High Pressure Water Jetting
    11.7 Flame Cleaning

  12. BS, ISO, SIS, NACE, SSPC Standards Relevant to Surface Preparation

    12.1 Rust Grades and Preparation Grades
    12.2 ISO, Swedish and British Standards on Surface Preparation
    12.3 ISO Standard on Localized Surface Preparation of Previously Painted Steel
    12.4 Inspection and Verification of Surface Preparation
    12.5 Procedure for the visual assessment of steel substrates
    12.6 Water jetting standard and the various flash rust grades
    12.7 Interpretation of the various blasting grades: Sa2, Sa2˝, Sa3, PMa, PSa2 & PSa2˝.
    12.8 ISO surface preparation standard for localized repair 

  13. Methods of Application

    13.1  Brush application
    13.2  Roller application
    13.3  Conventional air spray
    13.4  Airless spray
    13.5  Conventional spray vs. Airless spray: advantages and disadvantages
    13.6  Electrostatic spray
    13.7  Other methods of application

  14. Health and Safety Aspects

    14.1 MSDS and Product Data Sheet Review
    14.2 Flash point classification
    14.3 Fire Hazard and Fire Fighting Measures
    14.4 Hazardous ingredients
    14.5 General Precautions and First Aid

  15. Selection of Coatings

    15.1 Factors influencing coatings selection
    15.2 The process of coatings selection
    15.3 High chemical resistant coatings
    15.4 Moderate chemical resistant coatings
    15.5 Low chemical resistant coatings
    15.6 High temperature resistant coatings
    15.7 Special: zinc-rich coatings


  16. Coatings and Cathodic Protection

    16.1 How coatings protect steels from corrosion
    16.2 How cathodic protection works
    16.3 Coating failures induced by cathodic protection
    16.4 Coatings suitable for use with cathodic protection systems
    16.5 The economic aspect of specifying coatings with cathodic protection
    16.6 Cathodic protection criteria safe for coatings
    16.7 Laboratory and field test methods

  17. Coating Failures: Causes and Prevention

    17.1 Case studies: Arbitration & Litigation cases arising from coating failures
    17.2 Who pays when a coating fails
    17.3 The breakdown of coating failures
    17.4 Incorrect coatings specifications
    17.5 Application errors
    17.6 Change in environment from original design criteria
    17.8 Faulty paints
    17.9 Common coating failures: causes and prevention
    17.10 What the owner, applicator and supplier can do to minimize the risk of coating failures

  18. Coating Repair and Maintenance

    18.1 The need for coating maintenance and repair
    18.2 The timing of coating repair: WHEN to initiate a repair job
    18.3 Inspection to determine the extent of coating failure: ISO, ASTM, SSPC & European standards
    18.4 Standard Methods of Evaluating Degree of Rusting on Painted Steel Surfaces
    18.5 Repair procedure: ISO Standard
    18.6 Repair of common coating failures such as delamination, blistering, pinpoint rusting, chalking, etc.

  19. Development of Coatings Specifications

    19.1 Development of specifications
    19.2 Project specification
    19.3 Coatings specification
    19.4 Coatings work specification
    19.5 Inspection and assessment specification
    19.6 How to develop coatings specification for new work
    19.7 How to develop coatings specification for maintenance
    19.8 Contents of a specification
    19.9 Sample specifications for new work, maintenance and inspection

  20. Quality Control in Coatings Application

    20.1 The needs for quality control in coatings application
    20.2 Factors to be considered in quality control
    20.3 Variables involved in quality control
    20.4 Weather conditions

    20.6 In-process quality control

  21. Coatings Inspection and Testing

    21.1 The needs for inspection and testing
    21.2 Relevant international standards applicable to coatings inspection and testing
    21.3 The inspection requirements
    21.4 Preparation for inspection
    21.5 Laboratory and field test methods for surface cleanliness (water-soluble salts) after sandblasting
    21.6 Inspection and measurement of surface profile after sandblasting
    21.7 Measurement of Ambient Conditions &
    Environmental Test Instruments
    21.8 Nondestructive Testing and Inspection
    21.9 Nondestructive Testing Instruments
    21.10 Use of Inspection Procedures for Both Destructive and Nondestructive Test Instruments
    21.11 Laboratory Instruments and Test Methods
    21.12 Measurements of wet film thickness (WFT) and dry film thickness (DFT)
    21.13 Holiday detection
    21.14 Single coat vs multicoat
    21.15 Inspection Procedures
    21.16 Documentation and Logbook
    21.17 Inspection Checklist


  22. Glossary of Technical Terms in Coatings and Corrosion

  23. Course Examination


Course Outline |Who Should Attend |Registration |In-House |On-Demand |Online Courses |PPT Slides+Testbank |Course List

 Who Should Attend This Coatings Inspection and Repair Course

  • Engineers and technologists who are in charge of cathodic protection systems

  • Designers who are interested in cathodic protection technology for corrosion prevention

  • Technicians and maintenance personnel who deal with installed cathodic protection systems

  • Facility owners and users who are concerned with corrosion

Successful completion of this corrosion course helps participants prepare for their NACE certification examinations at the Corrosion Technician, Corrosion Technologist and Senior Corrosion Technologist levels.


 Registration for This  Corrosion Course


Click here to register for this corrosion course online, or

Click here to download this corrosion course brochure with registration form in PDF format.


 In-House Training Corrosion Courses


If you are concerned with corrosion in your company, in-house training or on-site training is a great solution to train a group of employees from design, production, operation, quality assurance, inspection and maintenance, and technical sales and support on corrosion control and corrosion prevention technology. The contents of all our corrosion courses can be customized to fit your organization's needs.


There is no limit to the number of participants required for in-house training corrosion courses. We conduct the in-house training corrosion course at your company's premises worldwide, and at a time convenient to your company.


Click here to contact us for a quotation for in-house training corrosion courses.

 Corrosion Course-On-Demand


All our publicly scheduled corrosion short courses are conducted once a year. However, you do not need to wait for one year if you have missed any of the publicly scheduled corrosion courses as we have this unique corrosion course-on-demand scheme: we will conduct the course just for you (on an one-on-one basis) or for a small group from your company at a time and in a location convenient to you. This option costs significantly less than a full-scale in-house or on-site corrosion training program.


Click here to contact us for a quotation.

 Online and Distance Learning Corrosion Courses


All our corrosion short courses are available for online or offline distance learning. You can start an online corrosion course at any time and learn at your own comfortable pace and schedule, whenever and wherever you are. You have around-the-clock access to the interactive and media-rich course materials, virtual labs, course instructions and course assessments. Discussions and questions related to the corrosion courses are posted on the website or exchanged through email for a period up to 3 months. Video conferencing or instant messaging can also be arranged for discussions of course topics. For those who do not have ready access to internet, we can send you our online course materials on a CD-ROM, or DVD, or USB flash drive for offline distance learning.


Click here to to register an online corrosion short course.

 PowerPoint Slides and Test Banks for Trainers, Instructors, Tutors, University Lecturers and Professors


If you are involved in teaching or training, you may wish to purchase a complete set of the trainer's package for this training course. The trainer's package comes complete with ready-to-use PowerPoint slides (fully editable) and test bank (with answer keys). These ready-to-use PowerPoint slides contain high quality color photographs, illustrations, animations, audio and video clips. The test bank contains questions conveniently grouped into four categories: (1) true or false, (2) multiple choice, (3) calculation, and (4) reasoning and open-ended discussions. The trainer's package is suitable for in-house training and university teaching (30 lecture hours). This is exactly the same package that WebCorr uses to deliver our current training course.

The one-time lump sum fee allows your organization to use the training package and also modify it. For example, your organization may modify the course contents and re-name/re-brand the course under your organization’s name. WebCorr only retains the copyright of the original PowerPoint slides and test banks.


Click here to contact us if you need more information on the trainer's package.

Course Outline |Who Should Attend |Registration |In-House |On-Demand |Online Courses |PPT Slides+Testbank |Course List

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