How Is a Coating Condition Survey Conducted?

How Is a Coating Condition Survey Conducted?

Blogs, Coating and Inspection Training

The eight-step coating survey methodology

Is a full coating condition survey necessary before applying a coating system? Isn’t understanding the environmental issues and operating in line with ISO 12944 enough?

In a short answer to these questions, imagine that your car is making strange noises from under the bonnet. You take it to two mechanics.

The first opens the bonnet, looks inside, taps the engine in a couple of places with a hammer, and then diagnoses the problem.

The second mechanic opens the bonnet, connects an electronic diagnostic machine, and invites you to have a tea while you’re waiting. Having received a computer printout, the mechanic then raises the car so he can look underneath. He makes a couple of phone calls, before presenting you with a detailed appraisal of the issue you have.

The question is this: which mechanic do you believe will provide the best, safest, longest-lasting, and most cost-effective solution? The one who carried out the most extensive and structured assessment, right?

In this article, we examine how an effective coating survey should be conducted to provide the knowledge needed to ensure the correct coating system is applied most cost-effectively.

When is a coating survey used?

A coating condition survey (or ‘coating survey’) should be used as a proactive measure in the protection of any previously coated structure. For example, this may include surveying coatings in the offshore environment or on bridges that are at risk of corrosion. Such proactive surveying will help to reduce maintenance costs, increase the integrity of infrastructure, and improve safety. A win/win/win.

Steps for successful surveying of coatings

To be effective, a coating survey must be designed, carried out in line with planning, recorded and reported. It’s essential to conduct coating surveys using a methodical and structured approach. This ensures that each survey benefits from the same rigorous standards. The following eight steps form the core of a coating condition survey.

1.     Planning the coating survey – what is needed?

It’s important to define the parameters of the survey before it is started. The information that is needed may depend upon factors such as:

  • Age of the asset
  • Time since the last coating survey
  • The value of the asset
  • When routine maintenance is due
  • If a new coating system will add value to the asset
  • Health and safety issues

2.     Planning the coating survey – what is the expected output of the survey?

The detail required of the survey should also be assessed. It is possible to produce a survey in too much detail. For example, consider an example of surveying the condition of a front door. Should you survey it as a single item, or assess each element separately? If the latter, then a survey will include each hinge, the letter box, the door knocker, each pane of glass, the inside and outside handles, the inserts, the frame, and the lock mechanism. One item becomes a survey of a dozen or more items.

If a survey is too detailed, it risks information overload and crucial details could be overlooked upon review. If not detailed enough, the survey may miss crucial details altogether.

3.     Planning the coating survey – how do you grade conditions?

The survey should carry out its assessment with a recognised and consistent grading system that establishes the severity of degradation of each component under the survey. The standards to which the assessment of coating/corrosion degrading must conform to are ISO 4624 parts 2-7 and the European Scale of Rusting for Anticorrosive Paint (commonly referred to as the Re Scale).

4.     Conducting the coating survey – note physical details

The survey should consider all the corrosive environmental issues that may affect the coating’s current condition. The location of the structure and the environmental factors associated with the location will affect how a coating performs. Factors include climate, moisture, and UV exposure.

5.     Conducting the coating survey – the original application

To better understand how the original coating has been affected by physical details, the survey should include key information about the original coating such as the date of application, the coating manufacturer, the applicator, and so on.

6.     Conducting the coating survey – note extraordinary events and occurrences

Over time, a structure’s coating may be affected by many events. These may include severe weather conditions, accidents, fire, maintenance, repairs, and refurbishment. The more detail that can be compiled within this section of the survey, the more informed the survey’s results will be.

7.     Conducting the coating survey – assessing the coating

The survey should move onto assessing the existing coating, considering adherence to the structure, dry film thickness, the percentage of failure across the system and its component parts, and the presence of aspects such as mill scale, chalking, pitting, etc.

8.     Recording and reporting – planning the next steps

The survey should record all details required of it, as set out in the planning steps. The survey should make recommendations as to:

  • Whether immediate maintenance is required
  • What maintenance should be planned for the next one to three years
  • The locations that are difficult to reach and which may require extra measures
  • Whether coating of an area may lead to the need for adjacent areas to be recoated

Answering these points will form the basis of a full coating maintenance programme that is designed to ensure asset integrity during the expected lifetime of the asset.

In Summary

A coating condition survey should form part of the routine maintenance checks for all structures on which protective coatings are used to combat corrosion. The survey should assess all components of the structure that have been identified as required to be surveyed, and assessment should be conducted in a manner that ensures consistency and completeness.

By following a consistent survey methodology, the survey should establish the current state of the existing coating, and the reasons for any degradation.

By monitoring the performance of a structure’s coating, an asset owner can understand the action needed to reduce the effects and consequences of corrosion. To ensure this, it is imperative that surveys are carried out by those with the training, experience, and qualifications to do so.

In our next article, we examine a world first that will define the coating survey professional and how industry carries out coating condition surveys in the future. In the meantime, to find out more about the Coating Survey Course, email the Institute of Corrosion or contact Corrodere.

How Is a Coating Condition Survey Conducted?

What Is a Coating Survey and Why Is it Crucial?

Blogs, Coating and Inspection Training

Assessing Structures to Improve Asset Integrity

In a world first, Corrodere has introduced a Coating Survey Course endorsed by ICorr and accredited by Lloyd’s Register and the Royal Society of Chemistry. Written by industry experts and presented and examined online, this course will set the standard for those who conduct coating surveys as part of their responsibilities.

In this article, we answer two key questions about coating surveys – what are they, and why are they needed?

Why is a coating survey needed?

To apply an effective coatings solution that will protect a steel structure against corrosion, coatings applicators must understand two things:

  1. The environmental factors that affect the structure
  2. The condition of the existing coating on the structure to be protected

ISO 12944 is the internationally recognised standard that covers coatings for steel structures in atmospheric, immersed, and buried environments. However, without conducting a survey of the existing condition of the structure, any coating system that is applied risks falling short of its primary objective – to maximise the protection offered by the coating system, thus ensuring that safety hazards and operational interruptions are avoided.

The only way that it is possible to gain a proper understanding of the existing structure’s coating is by examining. Thus, the need for a coating condition survey.

A coating survey is essential not only prior to a new coating being applied. It may also be conducted as preparation for regular maintenance and inspections for structural or coatings failures.

What answers does a coating survey provide?

A coating survey is the foundation of a successful application of a protective coating system. It provides crucial information that will help determine what preparatory work is needed, the maintenance required, and which coating system should be used.

The survey should provide information that covers the following elements:

  • The base material to which the coatings will be applied
  • Existing coating system used and its condition
  • If the existing coating material is hazardous
  • Repair and remedial work required prior to application of the new coating system

The survey should help to address questions that include:

  • Are there any special maintenance requirements needed, such as specialised removal of hazardous materials?
  • What has caused existing degradation and deterioration of the structure (for example, damage, age, environment)?
  • Is there any other maintenance and repair work required before protective coatings can be applied?
  • What will be the most cost-effective coating application that can be applied to achieve the objectives?

The benefits of coating surveys

Unfortunately, in many cases companies rely on surveys that are based upon a walk-through and visual assessment of a structure. Such inspections trust the instinct and experience of those conducting the survey, instead of standardised testing, sampling, and analysis.

Applying protective coating systems is a major maintenance function. An effective survey will help to ensure that this maintenance achieves what it should – to safeguard the structure and protect employees and others from the disastrous consequences of poor corrosion protection in infrastructure and transport.

In short, effective coating surveys save lives, ensure the integrity of a structure, and reduce costs as well as potential loss and reputational damage caused by avoidable accidents because of corrosion.

To learn more about this groundbreaking coating survey course and the benefits it offers to companies, contractors, and employees, you should contact Corrodere. Alternatively, email the admin team at the Institute of Corrosion who will be happy to help.

In our next article, we describe an eight-step coating survey methodology that will ensure a survey delivers its expected outcomes.

Meet the Corrosion Specialist – This Month, David Horrocks (FICorr)

Meet the Corrosion Specialist – This Month, David Horrocks (FICorr)

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11 Questions in 11 Minutes

It’s that time again when we get to ‘Meet the Corrosion Specialist’. This month we spoke with David Horrocks, Materials Engineer at BAM Nuttall Ltd., Chairman PDTC at the Institute of Corrosion, and Chairman of the training committee at NHSS19a Highways England. David is also a Fellow of ICorr.

As ever, we posed 11 questions for David to answer, encouraging him to invite us into his professional and private life. Here’s what he had to say.

1.     What did you aspire to be when you were younger?

A painter and decorator. My father said I needed to ‘get a trade’ when I left school. Things sort of went to plan as Dad wanted, but I left comprehensive school early and failed my mock exams! Luckily a local painting and decorating company, T. Taziker & Sons, was advertising for apprentices in Farnworth, Bolton. I was taken on, and attended Bolton College on Manchester Road one day each week. After four years, I had become a fully-fledged painter and decorator through the prestigious City & Guilds training scheme.

2.     So how did you end up as a corrosion specialist?

The painter and decorator life was superb. Hotel decoration, hospitals, wallpaper hanging, specialist spraying techniques, and high-end finishing… but the company wanted to utilise my skills not only to broaden my field of work but give me more managerial roles such as ‘foreman’, or ‘supervisor’.

As a young kid this was somewhat daunting, but I grabbed each opportunity with both hands. This led to new ventures in the industrial painting world. Blast cleaning and painting old steel structures –  including the Anderton Boat Lift in Cheshire and Tees Newport Bridge Middlesbrough – were milestones in a working career that was starting to showcase my passion for corrosion protection.

Inspection and management of projects really did take my career to another level, and gave me the platform to push for quality excellence in corrosion protection of steel structures.

3.     What was your first job like?

My first job was nothing to do with corrosion, painting, inspection, or management. I was a paperboy. Then I worked on the old electric milk float delivering milk!

In terms of my first job in corrosion mitigation, I suppose I realised that blasting old paint and rust off a very old bridge and spraying a new paint system on it that would protect it for a number of years to come was pretty cool.

4.     You decided to stick with blasting and painting, management and supervision. Why? Did you think this career was going somewhere?

My career progressed from blaster/sprayer to supervisor, manager, and inspector. I trained through ICorr and BGAS CSWIP and eventually gained ICorr Level 3.

Following a successful career in contracting from 1981-2006, I joined BAM Nuttall Ltd. as a Rail Managing Agent managing rail and highways infrastructure works. 2006-2020 has been spent helping industry in terms of corrosion control and how we manage this.

5.     What have yoICAA - industrial coatings apprenticeshipsu enjoyed most about your career in corrosion?

I suppose my biggest and most passionate enjoyment was the role I played in steering a new trailblazer industrial coating applicator apprenticeship scheme. This was a labour-intensive, three-year process, but every minute spent on this was worth the present-day fact that new apprentices are emerging!

(You can read about David’s part in the ICAA (Industrial Coatings Applicator Apprenticeship) programme here.)

6.     What career advice would you give to a young corrosion specialist?

That’s a difficult question. Every young person looking for a career will have a percentage of their thoughts as ideal job prospects, but for those candidates unsure on this industry and are wondering what the future holds, I would say don’t be afraid to approach us – but also bear in mind that a ‘corrosion specialist’ in the true form is not necessarily a specialist! He or she may have multiple skills and one of those may just be the ticket to a long and successful career.

7.     What is in store for corrosion professionals?

A life of change! Travel? Well maybe not so much now, but if you decide to be a corrosion specialist or just be involved in a corrosion-related career, you are certainly not going to be bored! ‘Corrosion’ – look it up!

8.     What have you gained from your membership of ICorr?

When I first gained my ICorr Level 1 Inspector certification, I was so pleased and personally proud to be part of an organisation that had peers such as David Deacon. Could I go higher?

The Institute offers routes to not only progress levels of professionalism such as ICorr Levels 2 & 3, but also offers professional status such as Technician (TICorr), Member, (MICorr), and the prestigious accolade of Fellow (FICorr). In addition to this, the Institute is recognised through other professional bodies such as NACE.

Let’s get personal

9.     What’s your favourite food?

Indian. Mind you, I’m a sucker for tapas.

10. What do you like doing most outside of your professional life?

Photography. I’m a keen photographer and love to capture wildlife. My other passion is cycling in Spain.

11. Tell us a secret about yourself, something that might surprise fellow members (and something we can print!)

I left school at 16, no qualifications, but knuckled down in life and did ‘OK’. But, I was a doorman bouncer in the late 80s – not really my thing.

But my biggest secret is that I have photographed numerous stars as a gig photographer.

(You can see a few on Instagram and on Facebook. We also persuaded David to ‘lend’ us a few of his photos of the Moon to accompany our article ‘The Moon is rusting’.)

What do you want to ask a corrosion specialist?

Wow! Where do we start? Our questions unveiled a lot about David! Who knew how far he’s come since leaving school at 16, working as a paperboy, and even as a doorman before his professional career in corrosion progressed so far?

Thank you, David, for a very interesting and inspiring interview for many budding corrosion professionals out there.

Right then, readers! What would you like us to ask the next ICorr member in our next ‘Meet the Corrosion Specialist’ interview? If you have a question for them, send us an email and we’ll try to get it answered.

ISO 12944-5:2018 – Protective Paint Systems

ISO 12944-5:2018 – Protective Paint Systems

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Setting Coating Specifications for Environment and Durability

Before undertaking surface preparation, it is critical that you consider the protective paint system to be used to protect the steel structure from corrosion. In this article, we continue our review of ISO 12944 with an overview of protective paint systems – Part 5 of the standard.

What is a protective paint system?

A protective paint system is a corrosion protection layer designed to protect the steel from the corrosivity of its surrounding environment (ISO 12944-2).

A paint system may include the following coats of paint:

  • Priming coat – the first coat of a coating system
  • Intermediate coat – any coat between the priming coat and the top coat
  • Tie coat – any coat which is used to improve the adhesion between coats or to eliminate void defects during paint application
  • Stripe coat – a further coat to increase thickness in vulnerable areas such as edges, welds, and threaded items such as bolted connections
  • Top coat – the last coat in the coating system

How do you select the appropriate protective paint system?

When considering which protective paint system, and, indeed, which type of paint should be used, you should consider the corrosivity of the environment, the structure itself, and durability requirements.

ISO 12944-2 details five environmental categories for onshore assets, from low corrosivity (C1) to very highly corrosive environments (C5). There is also a CX category that has been introduced to cover offshore environments, and which is described in a new section of the standard (part 9).

CX was introduced into the 2018 revision of the standard. In the previous version of ISO 12944, the C5 (severe) category of corrosion was split into two sub-sections: C5(I) for industrial environments and C5(M) for marine environments.

The C5(M) category clashed with another standard, ISO 20340, concerning the protection of offshore structures, which had a much more onerous test requirement. There was an anomaly with the relatively benign test regime for C5(M) which allowed the use of these systems in extremely severe corrosive environments such as offshore structures, leading to coating failures.

The 2018 revision of ISO 12944 has abolished C5(M) and now there is just C5 to represent a very severe onshore environment. ISO 20340 has been absorbed into ISO 12944 as a new section (Part 9), and the new corrosivity category of CX (extreme offshore) introduced for any structure that will be situated in an offshore marine environment with the more onerous test qualification regime; thereby closing the C5(M) loophole.

In addition, there are four categories for water and soil, as follows:

  • IM1 River installations and hydro plants (fresh water)
  • IM2 Immersed structures without cathodic protection (sea or brackish water)
  • IM3 Buried structures (soil)
  • IM4 Immersed structures with cathodic protection (sea or brackish water with cathodic protection)

The paint system used will also depend upon the structure and type of steel. For example, new structures are low-alloy steel as well as galvanised and metallized steel. The type of steel will be a determinant of the surface preparation undertaken as well as the appropriate paint system to employ to protect the structure from corrosion.

Where a steel structure is to be installed in a C1 environment, there should (at least in principle) be no need for a protective paint system. However, the structure may be susceptible to corrosion before it is installed, during transportation from the fabrication facility and the construction phases of the structure, and so may require temporary protection.

There may also be a decorative requirement for the steel structure that requires a paint system to be applied even though C1 poses little or no corrosion risk. Usually a C2 system will be specified in this case.

Durability definitions are provided in the first part of the standard, and depend upon several factors, including:

  • The structure’s design
  • The conditions during application
  • The environmental exposure after application
  • The surface preparation grade and work carried out
  • The condition of joints, edges, and welds prior to surface preparation

The paint system used should be appropriate for the period until the first major maintenance is due – its durability. Durability is expressed in terms of four ranges:

  • Low (L): up to 7 years
  • Medium (M): 7 years to 15 years
  • High (H): 15 years to 25 years
  • Very High (VH): more than 25 years

The durability range is not a ‘guarantee time’. Durability is a technical consideration/planning parameter that can help the owner set up a maintenance programme. A guarantee time is a consideration that is the legal subject of clauses in the administrative part of the contract. The guarantee time is usually shorter than the durability range. There are no rules that link the two periods of time.

Protective paint systems will be subject to many external influences such as weathering, mechanical damage, erosion etc. during their service life, and as such they should be regularly inspected and, if necessary, minor maintenance should be performed in order for the overall system to achieve its life to first major maintenance.

Types of Paint

The list of generic coating types in ISO 12944-5 5 is not intended to be exclusive or exhaustive. Other coating technologies not mentioned in the standard, including older traditional coatings or new innovative coatings may be classed as ISO 12944 conforming, provided that they have passed the qualification laboratory tests in Part 6, or have demonstrated a real-time track record in the given environment.

Coatings may be reversible or irreversible:

  • Reversible coatings dry by solvent evaporation, and the process can be reversed by re-dissolving in the original solvent.
  • Irreversible coatings dry by solvent evaporation (if a solvent is present) followed by a chemical reaction or coalescence. The coating cannot be dissolved in the original solvent or a solvent that would usually reverse the process.

Paints may be air-drying; waterborne; chemically curing; or moisture curing.

Dry film thickness

One of the key changes between the 2012/13 iteration and the 2017/18 iteration of the standard is the way that dry film thickness (DFT) is now treated by the standard. Previously the specified DFTs were provided as guidance. They are now mandatory normative minimum thicknesses.

Manufacturers had pushed DFTs for their products lower, to remain cost competitive. It was felt that this was creating a ‘race to the bottom’ and risking premature failure of protective paint systems. Therefore, the standard has been changed to require mandatory minimum DFTs.

ISO 12944-5 sets out recommended generic paint specification film thicknesses, which global experience has shown can give acceptable standards of corrosion protection for any given combination of durability period (L to VH) over the full range of corrosivity categories from C2 to C5 (CX is covered separately in Part 9).

The suggested paint systems are set out in a tabular fashion to indicate suggested product types and the minimum values for nominal DFT and the minimum number of coats required for the specification.

The systems in ISO12944-5 are not intended to guarantee proof of performance but have been arrived at by the considered judgement and experience of the international panel of industry and academic experts who worked on the ISO standard development.

Any proprietary paint specifications based on the model specifications that are laid out in ISO12944-5 MUST be verified by either laboratory pre-qualification testing as outlined in ISO12944-6; or have a proven track record of performance in the appropriate environment before they can be specified as being in accordance with the standard.

Should you apply protective paints systems on-site or in shop?

Finally, the standard also recommends that the complete protective paint system should, whenever possible, be applied in shop rather than on-site.

This approach enables greater control over the application in a controlled environment in which temperature and humidity are more stable, with better waste control and ease of repairing damage as well as easier access for the paint applicators to reach all areas of the components and for inspectors to reach and assess all areas of paintwork. Of course, this approach cannot be applied to aged structures that are being refurbished on-site.

To ensure your painters and inspectors are fully up to date with ISO 12944 and all of its parts and are working to the latest industry standards and best practices, the Institute of Corrosion offers Coating and Inspection Training Courses presented by IMechE Argyll Ruane and Corrodere. For more information, contact us today.

Meet the Corrosion Specialist – This Month, Kevin Harold

Meet the Corrosion Specialist – This Month, Kevin Harold

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11 Questions in 11 minutes

It’s that time again when we get to ‘Meet the Corrosion Specialist’, and this month we invited Kevin Harold, who is the Director of Paintel Ltd.

Here’s 11 answers from Kevin as he takes the hot seat of our infamous 11 Questions in 11 Minutes.

1.     What did you aspire to be when you were younger?

I went to school in Tottenham. When I was at school we were being prepared for factories and menial work. No one went to college or university. Therefore, my expectations were not much.

At that time, I was being looked after by my mum and the social services. Tottenham Borough Council came up with a nine-month training scheme – for young men in particular – to learn a trade. I was invited to a couple of meetings with my mum where I was presented with a list of trades. I chose painting and decorating. A couple of weeks later, 6th September 1976, I went to my first day of work.

I spent the next nine months learning about painting and decorating. This proved highly successful and I really enjoyed it, too. Three years later I had earned my City & Guilds in painting and decorating.

2.     So how did you end up as a corrosion specialist?

I had no qualifications from school as I didn’t go much, but decided some years later to go to night school and try and get some.

This I did, and part of the journey was studying chemistry as one of the subjects. That got me thinking about things differently – that and maths. I became extremely interested in chemical bonding, fusion of substances, and the creation of new ones. This led me to enquire as to how paint was working and what was happening at a molecular level. This stoked my ambition to become a painting inspector – which I did.

3.     What was your first job like?

My first job as a Painting Inspector was at Barking Power Station in London, in 1992. There were 50 blasters/painters on site at any one time. I had a lot of respect from the lads, because I was from the tools and had extensive knowledge of paints and coatings by this time.

4.     You decided to stick with paint inspection. How did your career progress?

I’ve worked mostly with structures. I worked with British Gas on gas holder projects for some time, and was heavily involved as an advisor and inspector during the redevelopment of docklands in London. Plus, I’ve worked on new prisons, on MOD contracts, with local authorities, Cardiff Bay Developments, and so on.

5.     What have you enjoyed most about your career in corrosion?

I have been able to work in most parts of the UK, choosing not to work overseas, and that has been excellent. I have found myself on wonderful structures, using amazing equipment, and enjoying that journey.

Most recently, August this year, I was one of the ‘End Point Assessors’ for the first ever Industrial Coating Applicators apprentices in the UK. I also wrote the technical information on which the apprentices were being assessed.

I spent a week assessing seven students, and it has become a treasured memory. It was an honour to be part of what was a big process with many ICorr people involved. All the apprentices received distinction.

6.     What career advice would you give to a young corrosion specialist?

For me, the biggest and most important aspect of what I do is understanding your subject matter. Learn your stuff. I memorised charts and standards. Then it would appear that I could tell people that black was white, and people would believe me.

7.     What is in store for corrosion professionals?

This business is most interesting. Corrosion is indeed fascinating, and not understood by most – even engineers. Learn your stuff and enjoy visiting different locations, even around the globe should you choose to. Of course, you will also enjoy a good salary and look after your loved ones.

8.     What have you gained from your membership of ICorr?

Meeting like-minded professionals at the top of their game. Being part of the ICorr team is wonderful, even by association. To be involved with a learned society is a great honour for me.

Let’s get personal!

9.     What’s your favourite food?

My favourite food is steak and chips with pepper sauce. I remember clearly my mum getting me steak the first time I was able to contribute to housekeeping when I was 16.

10. What do you like doing most outside of your professional life?

I love spending time with my family and friends, and my grandchildren, very much.

I also love running. I race in the UK and Europe.

11. Tell us a secret about yourself, something that might surprise fellow members (and something we can print!)

I have a brown belt in Karate and went on to train in multiple martial arts and fight on a weekly basis against other mixed martial artists before MMA existed. That will certainly surprise everyone!

What do you want to ask a corrosion specialist?

So, there you have it! Kevin has gone from strength to strength throughout his career, yet has always remained grounded, loves a steak, and will fight you for it with his martial arts skills.

Thank you, Kevin, for your involvement in ICorr and your contribution as a corrosion specialist.

Right then, readers! What would you like us to ask the next ICorr member in our next ‘Meet the Corrosion Specialist’ interview? If you have a question for them, send us an email and we’ll try to get it answered.

ICAA – The New Acronym Exciting the Industrial Coatings Industry

ICAA – The New Acronym Exciting the Industrial Coatings Industry

Blogs, Coating and Inspection Training

100% Apprentice Success Delivered by Jack Tighe Ltd.

In August 2020, seven apprentices at Jack Tighe Ltd. became the first to complete the new ICAA – Industrial Coatings Applicator Apprenticeship.

Running an apprenticeship scheme is a sizeable commitment. It must be done for the right reasons, and provide the potential to deliver your goals. It’s an even bigger undertaking when the apprenticeship scheme you are considering has not been tested elsewhere.

In this article, you’ll learn why Jack Tighe decided to take the apprenticeship route with the ICAA.

An apprenticeship that delivers to the needs of the employer

The industry is experiencing an increasing average age of coatings applicators, and Jack Tighe mirrors this. Concerned about the possible effects of a workforce getting nearer to retirement, the company undertook an analysis of its workforce to assess the scale of the issue.

What it found was disturbing. Almost a third of its workforce are aged between 55 and 65. With no new applicators coming through the company, and the whole industry experiencing the same issue, Jack Tighe’s forward-thinking management team could see big problems on the horizon.

Without new employees, natural employee attrition would soon leave a hole in their workforce.

“We looked at how we could fill this void for the future,” says Martin Hillyard, Chairman of the Jack Tighe Group. “We realised, though, that if we were to hire experienced employees, our new recruits would be likely to fall into the same age bracket as our existing employees,” Martin says. That wouldn’t solve the looming staffing issues.

They also determined that, without an apprenticeship programme in place, there was only one option available and that was to train new recruits through the Industrial Coating Applicator Training Scheme (ICATS).

The advantages of delivering apprenticeships

There are many benefits for employers who take on apprentices. These include:

  • Potential government incentives. Employers will receive £1,000 for each apprentice between 16 and 18 years of age. In certain circumstances, financial incentives are also available when an employer hires an apprentice aged up to 24 years old.
  • Another financial benefit is that the employer does not pay class 1 National Insurance contributions if the apprentice is under 25 years of age and earns below £827 per week.
  • Companies that pay into the Apprenticeship Levy have a fund to develop apprentices through a training course. Those who don’t pay into the Levy only need pay 5% of the course cost, with the remainder subsidised by the government.

For the apprentice, the experience and learning they receive provides a valuable and nationally recognised qualification. While learning, they are also earning.

The real benefit of employing apprentices

While all the above advantages clearly incentivise both employers to take on apprentices and employees to seek apprenticeships, for Jack Tighe there were two much bigger benefits.

“An apprenticeship programme will be a more long-term solution than hiring already qualified coatings applicators,” says Martin Hillyard. “But there’s also an additional benefit. We work with a blank canvas.”

Hiring and training apprentices meets Jack Tighe’s strategic goals of:

  • Upskilling its workforce
  • Shifting its workforce age demographic down
  • Growing and developing a workforce aligned to its company culture

Tailoring the training of apprentice industrial coatings applicators

Working with ICATS, Jack Tighe was also able to tailor its apprenticeship delivery to suit its unique needs.

“We could have an input into the type and standard of training to be delivered – which is tailored to our industry,” says Martin Hillyard.

The 18-month apprenticeship scheme started in 2018. Now completed, Martin reviews the apprenticeship with great satisfaction.

“We’re so very proud of the first ever industrial coatings apprentices in this country,” he said. “They all passed their End Point Assessment (EPA) with distinction.” That’s some achievement.

Of course, the proof of how worthwhile the experience has been is if the provider would repeat it. In this, Martin Hillyard has no hesitation.

“Considering the success of the first and second cohorts in the Industrial Coatings Applicator Apprenticeship, we have had no hesitation in deciding to recruit another 10 apprentices to commence in October 2020.

“In addition, we’re more than happy to include any other company’s apprentices on this course.”

We’re sure that making the decision to run the first ever apprenticeship scheme for industrial coatings applicators, with the 18-month course provided in association with DN colleges and the Institute of Corrosion, was a tougher decision to make than Martin Hillyard admits.

However, this first for the industry has proved to be a runaway success. To learn more about the ICAA, send an email to the admin team at the Institute of Corrosion. In the final part of this series detailing the design, delivery, and success of the ICAA, we examine how the apprenticeship was delivered at Jack Tighe.