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Free ultrasonic thickness testing report template

Free ultrasonic thickness testing (UT) report template (PDF-ready). Records readings, corrosion rates and remaining life for pressure vessels and piping.

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Updated 26 Oct 2026

Ultrasonic Thickness Testing Report

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UT measurement record for pressure vessels and piping with corrosion trend and remaining life.

#CML refLocation / descriptionNominal (mm)Min reading (mm)Previous (mm)Loss (mm)Rate (mm/yr)t-min (mm)Remaining life (yr)Result
e.g.-Excavator - 8 tonne-3,120------
1
2
3
4
5

The PDF includes all 20 numbered rows, ready to print or fill on screen.

How to use: download the PDF, print or complete digitally on any device.

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Jarrod Milford

Jarrod Milford

Co-Founder & Commercial Director

Updated 26 October 2026
Also see:Maintenance and work orders →Best CMMS software →MapTrack vs MaintainX →

Short answer

An ultrasonic thickness testing report records wall thickness readings at each condition monitoring location on pressure vessels, piping or tanks, with the instrument, probe, calibration, technician certification, corrosion rates and remaining life. NDT technicians complete it at each in-service inspection, at intervals set by the inspection code and corrosion rate. AS/NZS 3788:2024 clauses 4.4 and 4.5 cover time-based and risk-based intervals between pressure equipment inspections.

Checked against AS/NZS 3788:2024 (incl. Amd 1:2025) on by the MapTrack templates team. How we check templates

Key takeaways

  • The MapTrack ultrasonic thickness testing report template has 10 columns and room for 20 entries. Columns: CML ref, Location / description, Nominal (mm), Min reading (mm), Previous (mm), Loss (mm), Rate (mm/yr), t-min (mm), Remaining life (yr), Result.
  • Record the calibration block, probe frequency and verification readings on every report so each reading is traceable to a calibrated instrument.
  • Record both the short-term and long-term corrosion rates, the rate used for remaining life, and why that rate was chosen.
  • Model WHS Regulations reg 224: pressure equipment is inspected regularly by a competent person.
  • Flag step changes or unexpected wall loss for follow-up NDT such as phased array or radiography, and record the recommendation.
  • Record the technician's certification scheme and level; under SNT-TC-1A, a recommended practice, the employer writes its own written practice.

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Saunders InternationalMineral ResourcesSupagasHacer GroupMetro TunnelUltrabuilt

What is an ultrasonic thickness testing report template?

An ultrasonic thickness testing report template is a structured record used by NDT technicians and asset integrity engineers to document the results of UT measurements taken at designated condition monitoring locations on pressure vessels, piping, storage tanks, heat exchangers and other pressure-containing equipment. The report captures the equipment identification, the calibrated UT instrument and probe configuration, the surface preparation method, the couplant used, each measured reading at each condition monitoring location (CML), the minimum design thickness, the calculated short-term and long-term corrosion rates, the remaining life estimate and the next inspection due date.

UT measurement is a pulse-echo technique that uses high-frequency sound waves to determine the thickness of a material from one side, making it the standard non-destructive method for assessing wall loss in pressure-containing equipment without opening or removing the asset from service. In Australia the technique is applied within the AS/NZS 3788 in-service inspection framework and AS 4037 pressure equipment examination. Internationally the ASME B31 codes (B31.1 power piping, B31.3 process piping), API 510 (pressure vessel inspection), API 570 (piping inspection) and API 653 (tank inspection) reference UT thickness data as the primary input to fitness-for-service assessment, remaining life calculation and inspection interval decisions. Technicians performing UT must be certified to a recognised qualification scheme such as ASNT SNT-TC-1A in the United States, AINDT in Australia or PCN in the United Kingdom. A complete report gives the asset integrity engineer the evidence needed to declare the asset fit for continued service or to schedule repair, derating or replacement.

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Recording thickness readings on tanks and piping? See asset tracking solution for oil and gas for each item's inspection history.

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Benefits of using this ultrasonic thickness testing report template

  • Asset integrity evidence: documented UT readings at every condition monitoring location provide the objective wall-thickness data required for fitness-for-service assessments and inspection interval decisions under AS/NZS 3788, API 510 and API 570.
  • Corrosion trend visibility: comparing each reading against historical measurements at the same CML calculates short-term and long-term corrosion rates, surfacing accelerated degradation before it reaches retirement thickness.
  • Remaining life calculation: the difference between current thickness and minimum allowable thickness divided by the corrosion rate produces a remaining life estimate that drives replacement, repair and inspection scheduling.
  • Corrosion rate and remaining life: each CML row works out the loss since the last survey, the corrosion rate and the remaining life to t-min, the figures an integrity engineer needs, with the code that applies (ASME B31, API 510, API 570, API 653 or AS/NZS 3788), to set the next inspection.
  • NDT traceability: instrument serial number, calibration block, calibration date, probe frequency and couplant captured per reading ensure the data can be reproduced and audited by independent third parties.
  • Inspection scope coverage: the structured CML map ensures every required measurement point is captured rather than relying on technician recall, preventing missed locations that could mask localised corrosion.
  • Risk-based inspection input: UT data is the primary input to risk-based inspection (RBI) programmes under API 580 and API 581, with each measurement updating the probability-of-failure calculation for the asset.

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What to include in an ultrasonic thickness testing report template

This ultrasonic thickness testing report template covers 10 key areas:

  • Report header: report reference number, inspection date, asset owner, site, asset tag or registration number, equipment type (pressure vessel, piping, tank, exchanger), service fluid and operating conditions.
  • NDT technician details: technician name, certification scheme and level (AINDT, ASNT SNT-TC-1A, PCN), certification number, expiry date and signature.
  • Equipment details: manufacturer, year of manufacture, material specification, design pressure, design temperature, minimum design thickness, corrosion allowance and previous inspection reference.
  • UT instrument and calibration: instrument make and serial number, probe type and frequency, calibration block reference, calibration date, calibration verification readings, couplant and surface preparation method.
  • Condition monitoring location (CML) map: numbered diagram or reference showing every measurement point on the asset, with location description (shell strake 1 top, nozzle N1 6 oclock, elbow weld 1 inlet side).
  • Thickness readings: for each CML record the previous reading, current reading, minimum design thickness, short-term corrosion rate (mm/year), long-term corrosion rate (mm/year) and remaining life (years).
  • Pit and localised corrosion: separate section for pit depth measurements, area, severity and any required follow-up with phased array or radiography.
  • Fitness-for-service assessment: summary statement of whether the asset is fit for continued service, requires repair, requires retirement or requires more frequent inspection.
  • Next inspection due date: calculated next UT inspection due date based on corrosion rate and inspection interval rules under the relevant code.
  • Sign-off: NDT technician signature with certification details, asset integrity engineer review and approval signature.

How to use this ultrasonic thickness testing report template

  1. Plan the inspection and prepare the report header: review the asset history including design data, previous UT reports, repair records and corrosion rate trends, confirm the CML map covers every required measurement point and identify access requirements (scaffolding, confined space, hot work permit).
  2. Calibrate the UT instrument before inspection: select the correct probe frequency for the material thickness and surface condition, set up on a calibration block of matching material, verify range and sensitivity, record calibration block reference, calibration date and calibration verification readings on the report.
  3. Prepare each measurement surface: remove scale, paint or coatings to bare metal at every CML, apply couplant suitable for the surface condition and temperature, and check the surface is smooth enough for reliable acoustic coupling on the chosen probe size.
  4. Take each thickness measurement at every CML on the map: position the probe over the marked CML, take the reading, repeat to confirm repeatability and record the measurement against the CML reference along with the date, technician initials and any anomalies (echo loss, signal noise, suspected internal pitting).
  5. Calculate corrosion rates and remaining life for every CML: subtract the current reading from the previous reading and divide by the years elapsed for the short-term rate, repeat against the original baseline for the long-term rate, then divide remaining metal above minimum design thickness by the higher rate.
  6. Identify localised corrosion or pitting requiring further NDT: where readings show step changes, pit depths or unexpected wall loss, flag the location for follow-up with phased array, time-of-flight diffraction or radiography and record the recommendation in the report.
  7. Complete the fitness-for-service statement and sign off: based on the readings, corrosion rates and remaining life calculations, record whether the asset is fit for continued service, requires repair, requires derating or requires more frequent inspection, set the next UT inspection due date and submit for engineer review.

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How often should you complete this report?

UT inspection intervals are governed by the applicable inspection code and the calculated corrosion rate of the asset. Under API 510, pressure vessel UT inspection intervals are set at half the calculated remaining life or 10 years, whichever is shorter, with shorter intervals required for high-consequence service. API 570 sets piping UT intervals between 5 and 10 years depending on piping class and corrosion rate. API 653 sets tank UT intervals based on the corrosion rate of the lowest reading, with maximum intervals of 5 to 20 years.

AS/NZS 3788:2024 sets time-based external and internal inspection intervals for pressure vessels (clause 4.4), so check the current edition for the interval that applies, and UT thickness readings form part of both inspections. Equipment in highly corrosive service, with thin wall margins or with recent accelerated corrosion may require annual UT monitoring. Linking each UT report to the asset record in MapTrack ensures inspection due dates are scheduled automatically and corrosion trend data is preserved across multiple inspection cycles for fitness-for-service decisions and risk-based inspection programmes.

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Frequently asked questions

In Australia, AS/NZS 3788 sets the in-service inspection framework for pressure equipment and AS 4037 covers pressure equipment examination, both referencing UT thickness data as the primary wall-loss measurement. Internationally, the ASME B31 piping codes (B31.1 power piping, B31.3 process piping), API 510 (pressure vessels), API 570 (piping) and API 653 (storage tanks) all reference UT thickness readings as the input to remaining life and inspection interval calculations. NDT technicians performing the work must be certified to a recognised scheme such as ASNT SNT-TC-1A, AINDT or PCN at the relevant level.

UT thickness measurement is typically performed by technicians certified to Level 1 or Level 2 in ultrasonic testing under a recognised scheme. In the United States, ASNT SNT-TC-1A and ASNT CP-189 cover certification. In Australia, AINDT (Australian Institute for Non-Destructive Testing) provides certification under AS/NZS ISO 9712:2023 (which replaced AS 3998). In the United Kingdom, PCN (Personnel Certification in Non-Destructive Testing) is the standard scheme. Level 2 technicians can interpret results and write reports, while Level 1 technicians perform measurements under Level 2 supervision.

Short-term corrosion rate is calculated by subtracting the previous reading from the current reading and dividing by the time elapsed in years. Long-term corrosion rate uses the same calculation against the original baseline reading. Remaining life is calculated by subtracting the minimum allowable thickness from the current reading and dividing by the higher of the short-term or long-term corrosion rates. API 510 requires the next inspection to be scheduled at half the remaining life or 10 years, whichever is shorter, so the inspection interval shortens automatically as the asset ages.

A full pressure vessel inspection under AS/NZS 3788 or API 510 covers external visual examination, safety device verification, fittings inspection, UT thickness measurement and (where accessible) internal examination. UT thickness testing is one component of that broader inspection, focused specifically on measuring wall thickness at condition monitoring locations to calculate corrosion rate and remaining life. UT readings can also be performed as a standalone activity between full inspections to monitor accelerated corrosion or verify the condition of a specific area before deciding on repairs.

Yes. Digital asset integrity platforms such as MapTrack allow you to capture every UT reading against the equipment asset record, link the report to the inspection programme, calculate corrosion rates and remaining life automatically, schedule the next inspection based on code requirements and trend wall thickness across multiple inspection cycles. Digital records preserve technician certification, instrument calibration data and CML history for fitness-for-service decisions and regulator audits. Book a demo to see how MapTrack supports asset integrity management.

Plan the inspection and prepare the report header with the reference number, date and asset. Calibrate the instrument before the inspection and record the calibration. Prepare each measurement surface, then take a thickness reading at every condition monitoring location on the map. Calculate the corrosion rate and the remaining life for every location, identify any localised corrosion or pitting that needs further NDT, complete the fitness-for-service statement and sign the report off with the technician's certification details.

The interval is governed by the applicable inspection code and the calculated corrosion rate of the asset, not by a calendar alone. Under API 510 a pressure vessel's inspection interval is half the calculated remaining life or 10 years, whichever is shorter, with shorter intervals for high-consequence service. API 570 sets piping intervals of between 5 and 10 years depending on the piping class and the corrosion rate. Because the interval depends on the corrosion rate, every report should recalculate remaining life and state when the next inspection falls due.

The report reference number, the inspection date and the asset being inspected. The NDT technician's details, including name and certification scheme and level. The equipment details: manufacturer, year of manufacture, material and the design and nominal thicknesses. The UT instrument and its calibration: instrument make and serial number, the calibration block used and the result. Getting the header complete is what makes the readings that follow traceable to a person, an instrument and a calibration, which is what an auditor or an engineer reviewing the fitness-for-service statement will ask for.

Applicable regulatory standards

This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.

  • Pressure equipment - In-service inspection

    Edition: AS/NZS 3788:2024 (incl. Amd 1:2025)

    In-service inspection intervals, inspector qualification and the history record each reading feeds.

    • 4.4: Time-based intervals between pressure equipment inspections
    • 4.5: Risk-based inspection as an alternative basis for intervals
    • 3.6: Qualification of inspection personnel
    • 8.6: Keeping a history record for each item of pressure equipment

    Standards Australia and Standards New ZealandSold by the publisher

  • Model Work Health and Safety Regulations

    Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)

    Pressure equipment must be inspected regularly by a competent person.

    • reg 224: Pressure equipment must be inspected regularly by a competent person; inspected gas cylinders carry a current inspection mark.

    Safe Work Australia (drafted by the Parliamentary Counsel's Committee)

  • Non-destructive testing - Qualification and certification of NDT personnel

    Edition: AS/NZS ISO 9712:2023

    Qualification and certification of NDT personnel, the scheme behind the technician's level.

    Standards Australia and Standards New ZealandSold by the publisher

  • API 510 Pressure Vessel Inspection Code: In-service Inspection, Rating, Repair, and Alteration

    Edition: API 510, 11th edition (October 2022), with Errata 1 (March 2023) and Errata 2 (June 2025)

    US pressure vessel in-service inspection code that uses thickness data for remaining life and intervals.

    American Petroleum Institute (API)Sold by the publisher

  • API 570 Piping Inspection Code: In-service Inspection, Rating, Repair, and Alteration of Piping Systems

    Edition: API 570, 5th edition (February 2024), with Addendum 1 (October 2025)

    US piping in-service inspection code.

    American Petroleum Institute (API)Sold by the publisher

  • API STD 653 Tank Inspection, Repair, Alteration, and Reconstruction

    Edition: API Std 653, 5th edition (2014), with Addendum 4 (2025) and Errata 2 (2025)

    US standard for tank inspection, repair, alteration and reconstruction.

    American Petroleum Institute (API)Sold by the publisher

Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.

Ultrasonic thickness testing report template preview

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<div style="max-width:480px;font-family:system-ui,-apple-system,'Segoe UI',Roboto,sans-serif;border:1px solid #E5E7EB;border-radius:12px;padding:20px;background:#ffffff;">
  <p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
  <p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Ultrasonic thickness testing report template</p>
  <ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
    <li style="margin:4px 0;">Report header: report reference number, inspection date, asset owner, site, asset tag or registration number, equipment type (pressure vessel, piping, tank, exchanger), service fluid and operating conditions.</li>
    <li style="margin:4px 0;">NDT technician details: technician name, certification scheme and level (AINDT, ASNT SNT-TC-1A, PCN), certification number, expiry date and signature.</li>
    <li style="margin:4px 0;">Equipment details: manufacturer, year of manufacture, material specification, design pressure, design temperature, minimum design thickness, corrosion allowance and previous inspection reference.</li>
    <li style="margin:4px 0;">UT instrument and calibration: instrument make and serial number, probe type and frequency, calibration block reference, calibration date, calibration verification readings, couplant and surface preparation method.</li>
    <li style="margin:4px 0;">Condition monitoring location (CML) map: numbered diagram or reference showing every measurement point on the asset, with location description (shell strake 1 top, nozzle N1 6 oclock, elbow weld 1 inlet side).</li>
    <li style="margin:4px 0;">Thickness readings: for each CML record the previous reading, current reading, minimum design thickness, short-term corrosion rate (mm/year), long-term corrosion rate (mm/year) and remaining life (years).</li>
  </ul>
  <p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/ultrasonic-thickness-testing-report-template" style="color:#071D49;font-weight:600;text-decoration:none;">Ultrasonic thickness testing report template</a> by MapTrack</p>
</div>

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The MapTrack ultrasonic thickness testing report template has 10 columns and room for 20 entries.

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MapTrack Ultrasonic thickness testing report template, https://www.maptrack.com/templates/ultrasonic-thickness-testing-report-template
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MapTrack. (2026). Ultrasonic thickness testing report template [Checklist template]. Retrieved from https://www.maptrack.com/templates/ultrasonic-thickness-testing-report-template

Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/ultrasonic-thickness-testing-report-template.

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