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Failure Investigation & Root Cause Analysis

Unexpected failures can lead to costly downtime, safety hazards, and operational disruptions. Our multidisciplinary team uses scientific methodologies, metallurgical testing, and field expertise to identify the underlying causes of material, coating, or system failures.

We provide comprehensive investigation services that address failures in metallic and non-metallic materials, coatings, and corrosion protection systems — delivering actionable insights to enhance reliability and integrity.

Failure Investigation & Root Cause Analysis

Our Failure Investigation Services

Metallurgical Failure Analysis

Fractography, microstructural, and hardness examination
Identification of cracking mechanisms (fatigue, SCC, hydrogen embrittlement, etc.)
Chemical composition verification and microanalysis
Determination of manufacturing or fabrication defects

Corrosion Failure Investigation

Assessment of corrosion mechanisms such as pitting, crevice, galvanic, MIC, or erosion-corrosion
Evaluation of process conditions and corrosive media
Surface and deposit analysis using advanced lab techniques
Recommendations for mitigation and material improvement

Coating & Lining Failure Analysis

Examination of coating delamination, blistering, or underfilm corrosion
Evaluation of surface preparation, application, and curing defects
Adhesion, thickness, and holiday testing
Specification review and corrective coating recommendations

Pipeline & Asset Integrity Failures

Investigation of leaks, ruptures, and wall thinning
Analysis of internal/external corrosion and weld failures
Failure pattern mapping and corrosion rate estimation
Integration with cathodic protection and inspection data

Root Cause Analysis & Corrective Action Planning

Systematic RCA using methods such as 5-Why, Fishbone Diagram, or Fault Tree Analysis
Identification of contributing design, material, or operational factors
Development of corrective and preventive actions (CAPA)
Technical reporting with clear findings and recommendations

Our Investigation Process
Typical Failure Modes
Benefits & Outcomes

Data Collection & Site Inspection

Comprehensive gathering of operational data, maintenance records, and on-site evidence collection including photography, sampling, and environmental assessment.

Laboratory Analysis

Advanced metallurgical testing including microscopy, spectroscopy, mechanical testing, and chemical analysis to determine failure mechanisms and material properties.

Root Cause Identification

Systematic analysis using proven methodologies to identify underlying causes, contributing factors, and failure sequences through technical evaluation.

Reporting & Recommendations

Detailed technical reporting with clear findings, supporting evidence, and actionable recommendations for corrective and preventive measures.

Follow-Up Support

Ongoing technical support during implementation of recommendations, verification of effectiveness, and assistance with preventive program development.