Coatings Failure Analysis – Waste Water Treatment Works (WWTW)

Client: Regional Council
Project: Coatings Failure Analysis
Location: Regional NSW

Integrated Coating Services (ICS) was engaged to conduct third-party coatings inspection on a newly constructed Waste Water Treatment Works (WWTW) in regional New South Wales. Although coatings inspection is typically performed during application to ensure compliance, ICS was brought in after completion due to concerns about quality. The project involved assessing coating integrity in a highly aggressive environment where strict standards are essential to protect concrete infrastructure. ICS’s role was to evaluate the applied Ultra High Build Epoxy system against Water Services Association of Australia (WSAA) specifications, including WSA 201 and AS 2700.

Challenge

The contractor had completed coating works without implementing a robust quality assurance (QA) process. As a result, there was a breakdown in the verification of surface preparation and coating application. This oversight can lead to premature failure, costly remediation, and delayed commissioning. ICS was tasked with assessing the integrity of the finished work and identifying any non-compliance.

Solution

ICS deployed AMPP-NACE Certified Coatings Inspectors (CCI Level 2) to perform post-application QA testing. Holiday (spark) testing was used to detect discontinuities in the coating, while ultrasonic thickness (UT) testing measured dry film thickness across internal surfaces. Combined with a visual inspection these methods provided objective data on the applied system.

Implementation

Inspection was carried out across multiple underground structures, using calibrated equipment. Findings were documented in detailed reports, highlighting areas of non-compliance and failure. ICS provided clear recommendations for remediation aligned with WSAA standards.

Results

ICS’s inspection revealed significant deficiencies in the surface preparation and coating application, including areas of insufficient coverage and failed continuity. The absence of QA during the original works resulted in costly rework and delays. By identifying these issues before commissioning, ICS helped prevent long-term asset degradation and supported the contractor in restoring compliance.

This project highlights the critical importance of engaging qualified coatings inspectors early in the construction process.