COATING FAILURES AND REPAIR TECHNIQUES
Diagnosing Surface Degradation and Applying Effective Industrial Coating Solutions
Course Schedule
| Date | Venue | Fees (Face-to-Face) |
|---|---|---|
| 20 – 24 Apr 2026 | Istanbul, Turkey | USD 3495 per delegate |
Course Introduction
Protective coatings are critical to preventing corrosion, ensuring structural integrity, and extending the lifespan of industrial assets. However, improper application, surface contamination, or environmental exposure can lead to premature coating failures—costing industries millions in repairs, downtime, and safety risks.
This in-depth course equips engineers, inspectors, and maintenance professionals with the knowledge and techniques to identify coating failures, investigate root causes, and execute proper repair methods. Participants will explore surface preparation, material selection, defect analysis, and industry repair standards across multiple sectors.
Course Objectives
By the end of this course, participants will be able to:
• Recognize the types, symptoms, and causes of coating failures
• Conduct visual and instrument-based inspections of degraded surfaces
• Identify failures such as blistering, delamination, cracking, and rust creep
• Select appropriate repair methods and re-coating strategies
• Apply international standards (e.g., SSPC, NACE, ISO) in inspection and repair
• Enhance durability and performance through preventive coating practices
Key Benefits of Attending
• Diagnose and resolve coating problems before they compromise safety or operations
• Develop skills in inspection techniques and failure classification
• Apply repair procedures using industry standards and best practices
• Improve coordination with contractors, inspectors, and QA/QC teams
• Reduce recurring maintenance costs through better coating management
Intended Audience
This program is designed for:
• Maintenance and reliability engineers
• Corrosion and coating inspectors
• Asset integrity and facility managers
• QA/QC personnel in construction or oil & gas
• Anyone involved in protective coating applications and failure analysis
Individual Benefits
Key competencies that will be developed include:
• Failure mode identification and inspection readiness
• Knowledge of industry standards for surface preparation and coating repair
• Analytical skills in root cause investigation
• Hands-on repair planning and specification writing
• Proficiency in managing contractors and quality assurance
Organization Benefits
Upon completing the training course, participants will demonstrate:
• Improved detection and prevention of coating failures
• More cost-effective maintenance scheduling and repair execution
• Better compliance with industry codes and safety regulations
• Reduced rework and asset downtime
• Strengthened lifecycle performance of coated structures and equipment
Instructional Methdology
The course follows a blended learning approach combining theory with practice:
• Strategy Briefings – Coating types, failure mechanisms, and repair options
• Case Studies – Industrial failure scenarios across oil & gas, marine, and infrastructure
• Workshops – Visual inspection, specification review, and repair planning
• Peer Exchange – Shared challenges in coating management and QA/QC
• Tools – ISO/SSPC/NACE references, inspection kits, damage assessment forms
Course Outline
Training Hours: 7:30 AM – 3:30 PM
Daily Format: 3–4 Learning Modules | Coffee breaks: 09:30 & 11:15 | Lunch Buffet: 01:00 – 02:00
Day 1: Coating Systems and Failure Fundamentals
- Module 1: Introduction to Protective Coatings (07:30 – 09:30)
• Purpose, coating types, film build, performance expectations - Module 2: Coating Failure Mechanisms (09:45 – 11:15)
• Adhesion loss, underfilm corrosion, chalking, cracking - Module 3: Factors Contributing to Failure (11:30 – 01:00)
• Surface contamination, environmental conditions, application errors - Module 4: Workshop – Coating Failure Case Review (02:00 – 03:30)
• Analyze real failure photos and identify root causes
Day 2: Inspection, Testing, and Documentation
- Module 5: Visual and Instrument-Based Inspection (07:30 – 09:30)
• Dry film thickness, holiday detection, adhesion tests - Module 6: Inspection Standards and Procedures (09:45 – 11:15)
• ISO 8501, SSPC-VIS 1-3, NACE SP0188 - Module 7: Surface Preparation Assessment (11:30 – 01:00)
• Cleanliness grades, profile measurement, preparation methods - Module 8: Workshop – Conduct a Coating Inspection (02:00 – 03:30)
• Evaluate a coated panel and prepare inspection reports
Day 3: Repair Methods and Field Application
- Module 9: Localized vs Full Surface Repairs (07:30 – 09:30)
• Patch repair, recoating, full removal and replacement - Module 10: Selection of Repair Coating Systems (09:45 – 11:15)
• Epoxy, polyurethane, zinc-rich, marine coatings - Module 11: Application Tools and Field Practices (11:30 – 01:00)
• Brush, roller, airless spray, curing requirements - Module 12: Workshop – Specify a Repair Method (02:00 – 03:30)
• Write a procedure for repair of blistering and rust creep
Day 4: Prevention, Specification, and Contractor Management
- Module 13: Preventive Measures and Maintenance Coating (07:30 – 09:30)
• Coating selection, inspection intervals, coating audits - Module 14: Writing Coating Specifications (09:45 – 11:15)
• Surface prep, materials, environmental conditions - Module 15: Managing Contractors and QA/QC (11:30 – 01:00)
• Inspection checklists, approval stages, test reports - Module 16: Workshop – Review a Coating Specification (02:00 – 03:30)
• Evaluate an existing spec for completeness and accuracy
Day 5: Advanced Topics and Final Application Planning
- Module 17: Advanced Failures and Mitigation (07:30 – 09:30)
• Microbial corrosion, cathodic disbondment, UV degradation - Module 18: Sustainability and Environmental Compliance (09:45 – 11:15)
• VOC regulations, waste control, safe disposal practices - Module 19: Case Study – Major Repair Execution Plan (11:30 – 01:00)
• Step-by-step review of a refinery coating repair - Module 20: Final Workshop – Develop a Coating Repair Plan (02:00 – 03:30)
• Participants present a comprehensive repair and prevention plan
Certification
Participants will receive a Certificate of Completion in Coating Failures and Repair Techniques, validating their ability to inspect, diagnose, and manage coating failure scenarios using international best practices and industry standards.