Material Testing for Structural Integrity – Practical approach to understanding input data
Course Overview
Structural integrity is the backbone of safety and reliability in industries such as oil & gas, power generation, nuclear energy, transport, and infrastructure. Assets in these sectors operate under demanding conditions, high pressures, temperature extremes, corrosive environments, and fatigue loading, and understanding how materials respond to these challenges is critical for safe and economical operation.
Every Engineering Critical Assessment (ECA) or Fitness-for-Service (FFS) evaluation depends on reliable material property data. Parameters such as tensile strength, fracture toughness, impact resistance, fatigue crack growth, and creep behaviour are essential inputs in determining whether a detected defect can be safely accepted, repaired, or monitored. Yet, material data is only meaningful when it is accurate (tested to recognised standards), relevant (representative of in-service material conditions), and correctly interpreted (validated for use in BS 7910 or API 579 assessments).
This intensive 5-day training bridges the gap between laboratory testing and integrity assessments. Participants will learn not only how mechanical and fracture tests are conducted, but also how to critically evaluate and reduce test data into actionable inputs for defect assessments, life extension strategies, and Fitness-for-Service decisions.
Through a combination of technical lectures, case studies, and hands-on data-reduction exercises, delegates will develop the knowledge and confidence to make informed integrity judgments, directly supporting asset safety, compliance, and cost efficiency.
Why Attend?
- Understand how material testing underpins ECA and FFS assessments
- Learn to identify valid and invalid test data for use in structural integrity evaluations
- Build confidence in interpreting results for defect tolerance, inspection planning, and life extension
- Receive hands-on practice with real datasets from tensile, impact, fracture, fatigue, and creep tests
- Be guided by a UK-trained structural integrity expert with practical and academic experience
Learning Outcomes
By the end of this training course, participants will be able to:
- Explain the role of material testing in structural integrity, defect assessment, and life extension decisions.
- Describe key material properties including tensile strength, fracture toughness, impact energy, fatigue crack growth, and creep behaviour, and understand how they influence failure modes.
- Apply international test standards (e.g. ASTM, ISO, BS EN) to evaluate tensile, fracture, impact, fatigue, and creep tests.
- Perform data reduction and validation for use in Engineering Critical Assessments (ECA) and Fitness-for-Service (FFS) analyses in line with BS 7910 and API 579.
- Recognise sources of variability in test results and assess material representativeness (lab vs. service conditions).
- Interpret test outputs to support defect acceptance criteria, safe operating limits, and repair/replace decisions.
- Integrate test data into integrity workflows, including risk-based inspection (RBI) and life extension programs.
- Communicate findings effectively by preparing clear, defensible material test reports aligned with industry and regulatory expectations.
Daily Course Content
Day 1 – Foundations of Material Testing for Structural Integrity
- Introduction to structural integrity and the role of material testing.
- Overview of BS 7910 and API 579/ASME FFS-1 requirements for material properties.
- Stress–strain behaviour, tensile testing, and derivation of yield strength, ultimate strength, and elastic modulus.
- Standards for tensile testing (ASTM, ISO, BS EN).
- Case study: tensile test data reduction for use in defect assessment.
Day 2 – Fracture Toughness Testing and Assessment
- Principles of fracture mechanics in structural integrity.
- Fracture toughness parameters: KIC, JIC, CTOD.
- Specimen types (SENB, SENT, CT, mini-CT) and test methods.
- Validity requirements and interpretation of fracture toughness data.
- Application of fracture toughness in BS 7910 / API 579 defect assessments.
- Case study: converting test data into assessment input values.
Day 3 – Impact Testing and Fatigue Behaviour
- Charpy V-Notch testing: principles, ductile-to-brittle transition, and limitations.
- Correlation between Charpy energy and fracture toughness.
- Fatigue crack initiation and propagation mechanisms.
- Fatigue crack growth testing methods.
- Paris law and advanced crack growth models.
- Case study: predicting fatigue life using test data in an integrity context.
Day 4 – Creep and High-Temperature Behaviour
- Fundamentals of creep deformation and creep rupture.
- Test methods: uniaxial creep, stress rupture, and accelerated testing.
- Creep–fatigue interaction and implications for life assessment.
- Data interpretation: creep curves, stress exponent, and activation energy.
- Application of creep properties in defect acceptance and life extension studies.
- Case study: creep data integration into FFS workflows.
Day 5 – Integration, Data Reduction & Application to ECA/FFS
- Best practices in data validation and reduction for integrity use.
- Handling scatter, outliers, and material variability.
- Translating laboratory test data into BS 7910 and API 579 assessments.
- Worked example: complete dataset integration into a defect acceptance case.
- Reporting test results for regulators, clients, and internal integrity teams.
- Final group exercise and assessment: life extension case study.
Who Should Attend
This course is designed for professionals involved in structural integrity, testing, and asset management, including:
- Mechanical, materials, and integrity engineers working in oil & gas, petrochemical, nuclear, power generation, and transportation industries.
- Testing and laboratory engineers/technicians seeking to strengthen their understanding of standards, data interpretation, and integration into structural assessments.
- Asset managers and inspection specialists responsible for defect evaluation, Fitness-for-Service decisions, and life extension strategies.
- Consultants and researchers interested in the link between laboratory testing, fracture mechanics, and integrity assessment methodologies.
- Early-career engineers looking to build competence in material testing and its application to BS 7910 and API 579-based assessments.
A basic understanding of corrosion principles and oil and gas operations is helpful, but not essential. Fundamental concepts will be covered during the course.
Included Materials
- Comprehensive course manual covering testing standards, data reduction methods, and case studies.
- Worked examples and problem sets for hands-on practice with data interpretation and assessment workflows.
- Templates and checklists for test data recording, validation, and integration into BS 7910 / API 579 assessments.
- Access to electronic resources, including key references, example datasets, and industry guidance documents.
- Certificate of Completion, demonstrating competence in material testing for structural integrity applications.
Delivered by Specialists
This course is delivered by experienced practitioners in structural integrity, materials testing, and Fitness-for-Service (FFS). The instructors bring together academic expertise in fracture mechanics, fatigue, and material behaviour under extreme conditions, combined with hands-on laboratory experience in tensile, fracture toughness, fatigue, and creep testing to international standards. They also have extensive industry project backgrounds across oil & gas, power generation, nuclear, petrochemicals, and transportation sectors, as well as consultancy experience in Engineering Critical Assessments (ECA), Fitness-for-Service evaluations, and integrity management. This unique blend of research, testing, and industry practice ensures the training is practical, applied, and immediately relevant, equipping participants to confidently translate laboratory test results into real-world structural integrity and life extension decisions.
Key Benefits
- Bridge the gap between laboratory testing and real-world integrity assessments.
- Gain practical knowledge of material testing standards (ASTM, ISO, BS EN) and their application to defect assessment.
- Develop confidence in interpreting and reducing test data for use in BS 7910 and API 579/ASME FFS-1 assessments.
- Understand material behaviour under demanding service conditions including fracture, fatigue, impact, and creep.
- Learn from industry-experienced instructors with backgrounds in structural integrity, fracture mechanics, and Fitness-for-Service.
- Strengthen decision-making skills in defect acceptance, repair, or continued service of critical assets.
- Directly support asset safety, compliance, and cost efficiency, making you more valuable to your organisation.
Ready to master Material Testing for Structural Integrity – Practical approach to understanding input data?
Click the button below to book your training session today and become an expert in corrosion management and asset integrity systems for oil and gas operations.