Free ultrasonic thickness testing report template
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Free ultrasonic thickness testing (UT) report template (PDF-ready). Records readings, corrosion rates and remaining life for pressure vessels and piping.
Commercial Director
Updated 18 May 2026
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What is a 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 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.
Learn more about maintenance and work orders in MapTrack.
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.
- Code compliance: the report structure aligns with ASME B31, API 510, API 570, API 653 and AS/NZS 3788 reporting requirements, providing defensible evidence for regulator, insurer and certification body review.
- 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.
Benefits of digitising forms in MapTrack
When you digitise pressure vessel / pipe reports in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Automatically get alerts when faults are identified.
- Link every form digitally as a PDF to the relevant asset, location or person.
- Receive a digital PDF copy with every submission to your email.
- Ability to share forms digitally.
- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Restrict permissions (who can view, complete or approve).
- Build forms with AI (describe what you need and MapTrack suggests the form).
- Trigger work orders automatically when a fault is logged during an inspection.
- Track service intervals by hours, kilometres or calendar date in one place.
- Attach supplier invoices and parts receipts to each maintenance record.
Book a demo to see how MapTrack handles pressure vessel / pipe reports.
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What to include in a 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 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
- 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).
- 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.
- 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.
- 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).
- 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.
- 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.
- 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.
In MapTrack, you can schedule and track maintenance digitally. Each submission is stored as a timestamped PDF against the asset record.
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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.
Under AS/NZS 3788, pressure vessels are typically subject to external inspection every 3 years and internal inspection every 6 years, with UT thickness readings forming 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.
Frequently asked questions
Applicable regulatory standards
This template aligns with the following regulations and standards:
- AS/NZS 3788
- AS 4037
- ASME B31.1
- ASME B31.3
- API 510
- API 570
- API 653
- ASNT TC-1A
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<p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#0E7490;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 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>Please keep the “by MapTrack” attribution link in the snippet.
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