As coated steel and concrete structures age, small defects can quietly develop into serious corrosion problems, unplanned shutdowns, and expensive repair campaigns. Asset condition surveys focused on existing coating systems give owners a clear, data-driven view of their current risk so they can plan the right maintenance at the right time. For industrial facilities, commercial infrastructure, and marine assets, a structured survey is the foundation of an effective coating maintenance strategy.
What Is an Asset Condition Survey?
Definition and Focus
An asset condition survey is a systematic assessment of an existing coating system and substrate to determine its current condition, remaining life, and maintenance priorities. Inspectors evaluate the coating’s appearance, integrity, adhesion, and any visible or hidden signs of deterioration across agreed survey zones.
The survey combines visual inspection with non-destructive tests such as dry film thickness checks and holiday detection and may include limited destructive tests where required.
Why Asset Condition Surveys Matter
Managing Corrosion Risk
Protective coatings slow down corrosion, but atmospheric exposure, mechanical damage, and ageing gradually reduce their effectiveness. Without regular surveys, failures such as blistering, underfilm corrosion, and delamination may only be noticed once they require major intervention.
Routine condition surveys help identify early-stage defects so owners can implement targeted repairs and overcoating strategies before structural integrity or safety is compromised.
Planning Maintenance and Budgets
Survey findings feed directly into medium- and long-term maintenance planning. Reports typically highlight which areas require immediate attention, which can be scheduled within one to three years, and where simple monitoring is sufficient.
This prioritisation helps asset managers allocate budgets, plan access requirements, and coordinate shutdowns, rather than reacting to unexpected failures.
How an Asset Condition Survey Works
Step 1: Planning and Scoping
The process starts with defining the scope, assets, access method, and information needed. Inspectors review drawings, previous reports, and specifications, and agree survey zones and sampling levels based on risk and criticality.
Step 2: Visual Examination
On site, inspectors carry out a thorough visual assessment of all accessible surfaces. They look for typical coating defects such as rust staining, cracking, flaking, chalking, blistering, mechanical damage, and visible underfilm corrosion.
Step 3: Measurement and Testing
Where needed, destructive & non-destructive tests are performed to complement visual findings. Common techniques include:
- Dry film thickness measurements
- Holiday/pinhole detection on linings and high-risk areas
- Adhesion tests in selected locations
- Surface contamination checks during intrusive investigations
Step 4: Evaluation and Rating
Defects and measurements are grouped into zones and assigned condition ratings. The ratings reflect severity, extent, and likely impact on asset performance.
Step 5: Reporting and Recommendations
A final report summarizes survey methods, condition ratings, key risks, and recommended actions. It typically includes guidance on immediate repairs, planned maintenance over one to three years, and monitoring requirements.
Common Mistakes to Avoid
Waiting Until Major Failure
Delaying surveys until coating breakdown is widespread usually leads to more extensive surface preparation and full recoating or asset restoration instead of local repair. Regular surveys reduce lifecycle costs by enabling earlier, smaller interventions.
Surveying Without Clear Objectives
Running a survey without defined outputs (such as maintenance planning or life extension studies) can create reports that are difficult to apply. Clear objectives ensure that data, ratings, and recommendations match business needs.
Benefits and Use Cases
Key Benefits
- Improved understanding of coating and substrate condition
- Better prioritisation of maintenance budgets and shutdowns
- Reduced unplanned failures and emergency repairs
- Stronger evidence for regulators, insurers, and stakeholders
Typical Use Cases
- Bridges, tanks, and pipelines with ageing protective coatings
- Marine and offshore structures exposed to aggressive environments
- Industrial plants planning life-extension projects
- Assets being prepared for sale, refinancing, or regulatory review
FAQs
1. How often should an asset condition survey be carried out?
Frequency depends on environment and criticality, but many owners integrate surveys into routine maintenance cycles, often every few years for high-risk structures.
2. Do surveys always lead to full recoating?
No, surveys often support targeted repairs, overcoating strategies, or staged work, helping avoid unnecessary full recoating when the existing system is still performing acceptably in some areas.
3. Can hard-to-access areas be included?
Yes, access planning (scaffolding, rope access, MEWPs, or drones for visual checks) is part of the scoping phase so that critical areas are surveyed as safely and efficiently as possible. This will be No because access to be arranged for survey by the asset owner’s. (planning for future drone surveys)
Internal Link Suggestions
- Comprehensive coating inspection & quality testing
- Technical services & coating advisory
External Reference Suggestions
- coating condition survey best practices (authority corrosion or coatings institute)
- guidance on corrosion management for structures (relevant professional body)