Traditional inspection methods for coatings and material integrity require scaffolding, rope access or confined space entry which is time consuming, costly, and hazardous. Our drone inspection services overcome these challenges by capturing ultra high resolution data rapidly, without scaffolding or shutdowns.

• Capturing ultra-high-resolution data rapidly, without scaffolding or shutdowns
• Minimising human exposure to risk areas such as heights or hazardous environments
• Delivering repeatable, geo-referenced datasets ideal for trend analysis and maintenance planning
• Supporting both coating thickness measurement and material thickness measurement in a single integrated workflow

For asset owners seeking reliable industrial coating inspection, pipeline coating inspection, bridge coating inspection, or protective coating inspection, Sensoar offers a safer, faster, and more insightful solution than traditional access methods.

Coating Thickness Measurement & Mapping: our drones use advanced optical, ultrasonic, and laser sensors to perform coating thickness measurement over large surface areas. We generate high resolution DFT (Dry Film Thickness) maps to verify compliance, identify thin or over applied areas, and assess the remaining coating life. This data feeds directly into maintenance planning and quality assurance workflows.

Material Thickness Measurement: beyond coatings, understanding the actual material thickness of substrates such as steel, aluminium, or composite structures is critical for assessing corrosion rates and remaining service life. Using drone-mounted ultrasonic thickness sensors and laser profiling systems, Sensoar can measure the base material’s wall thickness with remarkable precision, even in challenging environments.

Applications include:

• Pipeline wall thickness monitoring: Detecting thinning or corrosion under insulation (CUI)
• Bridge and structural steel assessment: Checking for corrosion related wall loss in critical beams or plates
• Tank and vessel evaluation: Measuring both coating and base metal to determine total protection system effectiveness
• Marine and offshore structures: Monitoring hull or deck plate thickness in hard to reach zones

This combined material and coating thickness measurement capability enables asset owners to gain a full integrity picture, distinguishing whether corrosion originates in the coating or the substrate, and ensuring compliance with industry standards.

Our coating survey approach combines visual, infrared, and laser data collection to deliver a complete coating condition assessment. We identify defects such as blistering, flaking, corrosion creep, delamination, or under film corrosion. Drone acquired data is analysed by our ICorr qualified inspectors, who interpret coating health trends and produce detailed, actionable reports. Clients receive maps, imagery, and condition ratings with repair or re-coat recommendations.

From energy infrastructure to manufacturing plants, our industrial coating inspection services are designed to support continuous operation with minimal disruption. We inspect:

• Structural steelwork and tanks in refineries or chemical plants
• Transmission pipelines and risers via pipeline coating inspection
• Bridges, viaducts, and offshore installations using bridge coating inspection protocols

Each inspection combines visual imagery, thermal analysis, coating thickness measurement, and material thickness measurement for comprehensive integrity reporting.

When coatings fail prematurely, the root cause can be complex, involving application, environment, or material interaction. Our coating failure analysis process uses drone collected imagery and micro defect mapping to support laboratory testing and engineering assessment. We identify issues like improper surface preparation, film contamination, adhesion failure, or mechanical damage. The result: clear, evidence-based guidance for corrective actions and improved system performance.

Our drone services are optimised for diverse environments and asset types:

• Pipe coating inspection: Evaluating both coating and metal thickness along process lines
• Bridge coating inspection: Mapping corrosion, coating failure, and substrate loss without traffic closures
• Protective coating inspection: Covering offshore, wind, and industrial steel structures
• Pipeline coating inspection: Integrating wall-thickness data and coating condition in one workflow

• Dual coating & material measurement: We integrate both coating and substrate data for unmatched accuracy
• Fast mobilisation: Rapid deployment across the UK and internationally
• High-precision data: Laser and ultrasonic drones achieve sub-millimetre accuracy in many scenarios
• Expert analysis: Data interpreted by ICorr and materials engineers
• Reduced risk & downtime: Eliminate the need for scaffolding, rope access, or confined-space entry
• Actionable digital reports: Deliverables formatted for integration into maintenance systems or BIM models

All Sensoar inspection operations are led by ICorr qualified professionals and follow ISO and NACE/ICorr inspection standards. Our UAV pilots hold CAA certification, ensuring compliant, safe flight operations in complex or restricted airspace. Deliverables include:

• Annotated coating and material thickness maps
• Geo-tagged defect logs
• Coating grade and DFT compliance analysis
• Predictive maintenance recommendations

• Consultation & Planning: Define coating or material objectives, data resolution and site constraints
• Flight Planning & Risk Assessment: Airspace permissions and mission logistics
• Drone Inspection & Data Capture: Visual, infrared, and ultrasonic/laser data collection
• Data Processing: 3D modelling, DFT mapping, and wall-thickness computation
• Analysis & Reporting: Coating and material condition grading, failure detection, and recommendations
• Monitoring & Trend Analysis: Periodic re-flights for long-term coating condition assessment and wall-loss tracking

• Energy & Oil/Gas Pipelines: Combined pipeline coating inspection and material thickness measurement to prevent leaks and unplanned downtime
• Bridges & Infrastructure: Structural coating and wall-loss evaluation for life-extension projects
• Industrial Plants: Routine industrial coating inspection for tanks, towers, chimneys, and frames
• Offshore Platforms: Drone access for protective coating inspection and material integrity analysis in high-risk zones
• Failure Investigations: Evidence-based coating failure analysis to verify specification adherence

Effective coating and material integrity inspections protect your assets and reduce lifecycle costs. By combining coating thickness measurement with material thickness measurement, Sensoar offers asset owners complete visibility over corrosion performance and protection system health enabling informed, proactive decisions.

Searching for coating inspection companies near you?

Choose providers offering:

• Certified coating inspectors (ICorr, NACE, SSPC)
• Coating inspection with high-precision data capture
• Integrated coating and material analysis
• Proven reporting accuracy and fast mobilisation

Sensoar delivers all this with UK wide and international coverage.

From coating survey and protective coating inspection to advanced material thickness measurement, Sensoar provides the technology, expertise and reporting power to protect your critical assets. Contact us today to discuss your requirements for industrial coating inspection, pipeline coating inspection, or bridge coating inspection and experience how drone technology and engineering precision redefine asset integrity.

Sensoar redefining coating and material inspection with drone technology and engineering excellence:

• Coating thickness measurement
• Material thickness measurement
• Coating survey & condition assessment
• Industrial coating inspection
• Pipeline & bridge coating inspection
• Protective coating inspection
• Coating failure analysis
• Comprehensive inspection reports