ICorr Coating Inspector Assessment Guidelines

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 This document details how a student using the Corrodere online coating inspector training programme can
progress through the Institute of Corrosion Coating Inspector Certification levels 1, 2 and 3.

The document will guide the student in the knowledge requirements for each level.

ICORR REQ Doc Level 2

Level 2 personnel are qualified to perform and direct
The ICORR REQ Doc is the ‘requirements for the inspection or testing operations according to established
certification of personnel engaged in painting and coating or recognise procedures and they have demonstrated
inspection, cathodic protection and related fields’. The competence to:
document is wholly owned and administered by the
Institute of Corrosion. -- Choose the extent of inspection or testing to be used
(where agreed procedures allow)
The ICORR REQ Doc is a document which establishes a -- Choose the inspection and test methods to be used
system for the qualification and certification and sets out (where agreed procedures allow)
the requirements common to all parts of the scheme.
-- Set up and calibrate inspection or test equipment
The Corrodere online training programme works in -- Perform and supervise inspection or testing tasks
accordance with the ICORR REQ Doc. A quality system -- Interpret and evaluate results according to applicable
approved by Lloyds training ensures that procedures are normative documents
available and managed in accordance with ISO 9001.
-- Define the limitations of application for common test
A student may progress directly onto ICorr Level 2 if methods
they can demonstrate they have coating experience, -- Understand and transform normative document
practical instrument experience and completed the requirements into practical instructions adapted to the
Traintheinspector online training programme. If a student actual working conditions
fails Level 2 they will not get a Level 1 certificate by -- Prepare written test instructions
default.
-- Organise and report the results of inspections or tests
Level 3
Level 3 personnel are qualified to:
Levels of Certification -- Direct any inspection or test operation for which they
The ICorr Req Doc has three levels of certification which are certified
are defined as follows: -- Assume full responsibility for an inspection or test
facility and staff
Level 1 -- Establish and / or validate work instructions or
Level 1 personnel are qualified to carry out operations procedures
according to written instructions. ICorr Level 1 certified
-- Interpret normative documents
personnel have demonstrated the competence to:
-- Designate the extent of inspection and the particular
-- Set up and calibrate specific inspection or test
test methods and procedures to be used
equipment
-- Carry out tests and perform inspections against written Level 3 personnel have demonstrated:
criteria: -- Competence to interpret and evaluate inspection or
test results in terms of existing normative documents
-- Record and classify the results of tests and inspections
against written criteria: -- Possession of a cope and level of knowledge sufficient
to enable the individual to select inspection methods
-- Report the results
and tests, and to assist in the establishment of
Level 1 personnel have not demonstrated competence inspection and test criteria where non are otherwise
in selecting the extent of inspection or testing required, available
appropriate inspection or test methods to be used, nor
-- A general familiarity with all coating materials,
for the interpretation of specification requirements.
application methods and associated areas
-- The ability to guide personnel below level 3.
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Qualification examinations Examination Invigilator
The ICorr Req Doc outlines the examinations which All exams will be conducted in strict accordance with
consist of general, specific and practical questions. control procedures and with the use of an ICorr Approved
Invigilator.
The general and specific examinations consist of both
multi-choice and essay type questions. The student must obtain at least 70% in both general
and specific parts of the examination and 80% on the
General questions – technology, principles, physics practical.
chemistry and mathematics

Specific questions – equipment, operating procedures and Practical Assessment Workshop

test techniques Corrodere have developed a one day training course for
students who wish to have a practical training session on
LEVEL NUMBER OF GENERAL QUESTIONS all the Coating Inspection Instruments that will be found
Multi-choice 40 - Maximum 60 minutes in the practical assessments, specifically for ICorr Level
Level 1 1Coating Inspector.
Essay 5 - Maximum 75 minutes

Level 2
Multi-choice 40 - Maximum 60 minutes Training Units
Essay 5 - Maximum 75 minutes
The student must complete the online training units and
Multi-choice 60 - Maximum 90 minutes
Level 3 tests with 100% before applying for examination at any
Essay 10 - Maximum 150 minutes level.
LEVEL NUMBER OF SPECIFIC QUESTIONS
Revision Guidelines
Multi-choice 30 - Maximum 45 minutes
Level 1
Essay 4 - Maximum 60 minutes ICorr Level 1 - Students must revise the full syllabus on
Multi-choice 30 - Maximum 45 minutes www.level1.traintheinspector.com
Level 2
Essay 4 - Maximum 60 minutes ICorr Level 2 & 3 - Refer to the key below and highlighted
Multi-choice 40 - Maximum 60 minutes student study material overleaf for revision guidelines.
Level 3
Essay 5 - Maximum 75 minutes
LEVEL 2 KEY
Questions for ICorr Level 2 are likely to be
Practical Examinations asked on these training units, however these
will be in greater depth than ICorr Level 1.
There is a different type of practical Questions for ICorr Level 2 will be selected
assessment for all three levels: from these training units.

Level 1 – Hands on practical assessment of inspection No questions for ICorr Level 2 will be selected
equipment: from these training units.
LEVEL 3 KEY
-- Environmental equipment
-- Wet and dry film thickness gauges Questions are likely to be asked on these
training units for ICorr Level 3, however these
-- Holiday detection
will be in greater depth than ICorr Level 1 and
-- Surface profile 2.
-- Surface contaminants (salt, dust etc) Questions for ICorr Level 3 will be selected
-- Preparation identification from these training units.
-- Visual standards
-- Types of abrasives

Level 2 – Preparation of written instructions for Level 1

personnel (1 hours)

Level 3 – Preparation of a written procedure involving

inspection and testing for a work situation (4 hours).

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Student Study & Revision Material
Protective coatings application
LEVEL 2 LEVEL 3 LEVEL 2 LEVEL 3
1 Health and safety 3.6.1 Introduction to High Pressure Water Jetting
1.1 Company induction 3.6.2 BS EN ISO 8501-4
1.2 Accident prevention 3.6.3 SSPC VIS 4 - NACE VIS 7
1.3 House keeping 4 Coating types
1.4 First aid 4.1 Coating types and systems
1.5 Electricity and air supply 4.2 Products data sheets - review
1.6 Permit to work 4.3 Single and two part materials
1.7 Risk assessment 4.4 Paint mixing
1.8 Material data sheets 4.5 Pot-life and induction
1.9 LEL, TLV, OEL MEL 4.6 Storage
1.10 PPE 4.7 Batch numbers
1.11 Basic access requirements 4.8 Volume solids
1.12 Safety in surface preparation 4.9 Coverage
1.13 Safety in paint application 4.10 Compatibility
1.14 Method statements 5 Coating application
1.15 Confined Spaces 5.1 Environmental conditions
1.16 Health and Wellbeing 5.1.1 Relative humidity and dew point
2 Access, plant and equipment 5.1.2 Steel temperature
2.1 Erecting and dismantling platforms 5.2 Types of paint application equipment

2.1.1 Erecting and dismantling platforms 5.2.1 Brush application

2.1.2 Safe use of ladders 5.2.2 Roller application

2.2 Types of mobile access 5.2.3 Airless spray (introduction)

2.2.1 Access platforms 5.2.4 Air assisted spray (introduction)

3 Surface preparation 5.3 Paint film thickness

3.1 Surface preparation requirements 5.3.1 Wet film thickness

3.1.1 Types and methods of surface preparation 5.3.2 Dry film thickness

3.1.2 Types of substrates and materials 5.3.3 Drying and re-coating

3.1.3 Previously painted and coated substrates 5.3.4 Stripe coating

3.2 Surface preparation standards 5.4 Paint application procedures
3.2.1 Mechanical and hand preparation standards 5.4.1 Surface cleaning
3.2.2 Pre-surface condition 5.4.2 Coatings damage and repair
3.2.3 Pre-surface preparation and cleaning 5.4.3 Materials and equipment handling
3.3 Hand and power tool equipment 5.5 Paint locations and types
3.3.1 Chipping hammer 5.5.1 Shop painting
3.3.2 Hand wire brush 5.5.2 Site painting
3.3.3 Scraper 5.5.3 General maintenance - plant and equipment
3.3.4 Needle gun 5.5.4 Equipment cleaning
3.3.5 Power wire brush and grinding 5.5.5 Maintenance Painting Operations
3.4 Pre-cleaning methods 6 Quality control
3.4.1 Steam cleaning 6.1 Environmental conditions inspection
3.4.2 Water washing equipment

3.4.3 Solvent cleaning 6.2 Inspection standards

3.5 Auxiliary equipment 6.2.1 BS, EN, ISO etc

3.5.1 Compressors 6.2.2 Visual standards

3.5.2 Heaters 6.3 Specification

3.5.3 Lighting 6.4 Paint Manufacture

3.5.4 Grit removal and hoppers 6.5 Inspection and Test Equipment

3.5.5 De-humidification 6.5.1 Inspection and Test Equipment

3.6 Water Jetting 6.5.2 Documentation

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 LEVEL 2 LEVEL 3
7 Metallic coatings
7.1 Thermal metal spray for corrosion protection
7.2 Galvanizing
8 Intumescent coatings
8.1 Thin film intumescent coatings
8.2 Thick film intumescent coatings
9 Concrete
9.1 Concrete basics
9.2 Concrete moisture
9.3 Concrete preparation
9.4 Concrete coatings
10 Environmental
10.1 Volatile organic compounds
10.2 Hazardous waste
11 Coating failure
11.1 Coating failures
12 Management and supervision
12.1 Management and supervision
13 Offshore and marine
13.1 Offshore
13.1.1 Offshore construction
13.1.2 Offshore maintenance
13.2 Dry docking procedures
13.2.1 In-docking specification and surface
preparation
13.2.2 Coating application and undocking
13.3 Marine coating systems
13.3.1 Outside shell coating systems
13.3.2 Cargo tank coating systems
13.3.3 Cargo hold coating systems
13.3.4 Superstructure coating system
13.3.5 Main deck coating system
14 Speciality units
14.1 Specialist coatings
14.2 History of pipe coatings
14.3 Fusion bonded epoxy coatings for pipeline
protection
14.4 Miscellaneous pipeline coatings and field joints
14.5 Rubber linings
14.6 Special coatings and linings
14.7 Powder coatings
15 Visual standards
15.1 BS EN IOS 8501-1
15.2 BS EN ISO 8501-2
15.3 BS EN ISO 8501-3
15.4 BS EN ISO 8501-4
15.5 SSPC VIS 1
15.6 SSPC VIS 3
15.7 SSPC VIS 4 - NACE VIS 7
15.8 SSPC VIS 5 - NACE VIS 9

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Abrasive blast cleaning Spray painting
LEVEL 2 LEVEL 3 LEVEL 2 LEVEL 3
1 Introduction 1 Introduction
1.1 General overview 1.1 Paint application (introduction)
1.2 Basic corrosion 1.2 Basic corrosion
1.3 Mill scale 1.3 Surface preparation
1.4 Substrate materials 1.4 Coating types and systems
1.5 Pre-surface condition 2 Health and safety
1.6 Mechanical blast cleaning equipment 2.1 Material safety data sheets
1.7 Types of air blast equipment 2.2 Risk assessments
1.8 Wet abrasive blast cleaning 2.3 Method statements
2 Health and safety 3 Paint materials
2.1 Health and safety (introduction) 3.1 Product data sheets - review
2.2 Method statements / risk assessments 3.2 Paint storage and paint mixing
2.3 Personal protection equipment (PPE) 3.3 Quality control
2.4 Breathing air / helmets 4 Airless spray equipment
3 Blast media 4.1 Airless spray painting equipment
3.1 Types of abrasives 4.1.1 Airless spray painting equipment - A
3.2 Surface profile 4.1.2 Airless spray painting equipment - B
4 Standards and quality control 4.2 Equipment set-up, testing and general use
4.1 Visual (photographic) standards 5 Conventional air spray
4.2 Surface cleanliness 5.1 Conventional air spray equipment
4.3 Environmental conditions 6 Plural component spray
5 Operational procedures 6.1 Plural spray
5.1 Compressed air and air requirements
5.2 Blast hose and associated equipment
5.3 Types of nozzle
5.4 Ventilation and lighting
5.5 Communication
6 Process control
6.1 Equipment set-up and testing
6.2 Abrasive blast cleaning process
6.3 Abrasive blast cleaning standards/guides

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Specialist Units
LEVEL 2 LEVEL 3
LEVEL 2 LEVEL 3
6.1.4 BS EN ISO 8502 Part 2
1 Coating Inspection and Inspection Equipment
6.1.5 BS EN ISO 8502 Part 3
1.1 Inspection and Testing Equipment
6.1.6 BS EN ISO 8502 Part 4
1.2 Duties of a Painting Inspector
6.1.7 BS EN ISO 8502 Part 5
1.3 Low Voltage Holiday Detector
6.1.8 BS EN ISO 8502 Part 6
1.4 High Voltage Holiday Detector
6.1.9 BS EN ISO 8502 Part 8
1.5 Practical Arithmetic
6.1.10 BS EN ISO 8502 Part 9
1.6 Pre-Job Conference
6.1.11 BS EN ISO 8502 Part 11
1.7 Navigating Coating Specifications
6.1.12 BS EN ISO 8502 Part 12
1.8 Inspection Plans
6.1.13 BS EN ISO 8503-1
1.9 The Roles of QA and QC Inspector
6.1.14 BS EN ISO 8503-2
1.10 Inspection Documentation
6.1.15 BS EN ISO 8503-3
1.11 Coating Inspectors Safety
6.1.16 BS EN ISO 8503-4
1.12 Advanced Non-destructive Tests
6.1.17 BS EN ISO 8503-5
1.13 Advanced Destructive Tests
6.1.18 BS EN ISO 8504-1
2 Corrosion, Cathodic Protection and Coatings
6.1.19 BS EN ISO 8504-2
2.1 Corrosion Fundamentals
6.1.20 BS EN ISO 8504-3
2.2 Forms of Corrosion
6.1.21 BS EN ISO 2409 (BS3900-E6)
2.3 Engineering Materials
6.1.22 ISO Miscellaneous
2.4 Environments
6.2 SSPC Standards
2.5 Cathodic Protection in the Marine
Environment 6.2.1 SSPC VIS 2

2.6 Cathodic Protection of Pipelines 6.2.2 SSPC – PA1

2.7 Cathodic Protection and Coatings 6.2.3 SSPC – PA2

3 Marine General 6.2.4 SSPC Miscellaneous

3.1 IMO Regulations – Ballast Tanks 6.3 ASTM Standards

3.1.1 Performance Standards for Protective 6.3.1 ASTM D 4541

Coatings: Part 1 6.3.2 ASTM D 6677
3.1.2 Performance Standards for Protective 6.3.3 ASTM D 3359
Coatings: Part 2
6.3.4 ASTM D 4417
3.1.3 Performance Standards for Protective
6.3.5 ASTM – Miscellaneous Standards
Coatings: Part 3
6.4 NORSOK Standards
3.1.4 Performance Standards for Protective
Coatings: Part 4 6.4.1 NORSOK M-501

3.2 High Pressure Water Jetting on Sea Going 7 Quality Management

Vessels 7.1 Quality Management System
3.3 IMO Regulations Cargo Oil Tanks 8 Paint Testing
3.4 IMO Regulations Void Spaces 8.1 Laboratory and Field Testing
3.5 IMO Guidelines for Maintenance and Repair 8.1.1 Laboratory and Field Testing – Part 1
of Coatings 8.1.2 Laboratory and Field Testing – Part 2
3.6 Coating Survey Guide for ballast tanks 8.2 Paint Testing, Paint Constituents and Paint
4 Marine PSPC Chemistry
4.1 Role of the Inspector 8.2.1 Paint Testing, Paint Constituents and Paint
4.2 International Standards Chemistry Part 1

4.3 Coating Technical File 8.2.2 Paint Testing, Paint Constituents and Paint
Chemistry Part 2
4.4 Ventilation and De-humidification
9 Soluble Salts
4.5 Pre-job Conference
9.1 Soluble Salts
5 Design & Construction
10 Specialist Tests
5.1 Material Design and Type
10.1 Specialist Tests and Test Equipment
6 ISO and other International Standards
11 Coating Surveys
6.1 ISO Standards
11.1 Coating Surveys
6.1.1 EN ISO 12944 (Parts 1-8)
6.1.2 EN ISO 4624
6.1.3 EN ISO 4628 (Parts 1-6)

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 3855 0317

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