At OnestopNDT, we are honored to feature Dr. Vijesh Vijayan, Managing Director of The Anti Corrosion Experts (ACE). A distinguished coating inspection specialist corrosion engineer, researcher, and industry thought leader, Dr. Vijesh brings over 15 years of multidisciplinary experience spanning protective coatings, tank linings, marine coatings, fireproofing, thermal spray aluminum , pipeline coatings, corrosion management, inspection, and asset integrity.
From humble beginnings as an airless painter and blaster to becoming a globally recognized authority in coatings and corrosion engineering, his journey reflects both technical mastery and visionary leadership. His expertise covers coating surveys, root cause analysis, failure investigations, and technical consulting, enabling him to deliver sustainable, high-performance solutions across oil & gas, marine, offshore, and infrastructure sectors.
Under his direction, ACE has grown into a trusted name known for advancing innovation, cost-effective strategies, and long-term corrosion protection.
In this interview, Dr. Vijesh shares his professional journey, academic achievements, ACE’s growth story, the evolving challenges of corrosion control, and his vision for shaping the future of coatings and corrosion protection worldwide.
Dr. Vijesh, welcome to OnestopNDT. It’s a pleasure to have you with us today. Could you begin by sharing your professional journey, from your early days as a coating inspector and technical advisor to your current role as Managing Director of The Anti Corrosion Experts (ACE)?
First of all, thank you very much for having me; it’s truly an honor to share my journey here on OnestopNDT.
I was born and raised in Kerala, where I completed my vocational diploma in Mechanical Engineering. Entering this industry 15 years ago was not easy. As a beginner, opportunities were limited, but when I got my first break in the coatings and corrosion field, I quickly realized the vast potential and depth this industry offered.
I began my career as an Airless Spray Painter and Blaster at Cochin Shipyard, working with a well-reputed company based in Qatar. During this time, I gained invaluable hands-on experience in surface preparation, application techniques, paint systems from different manufacturers, client specifications, and strict quality control requirements. Those early years instilled in me discipline, precision, and resilience—qualities that continue to guide me today.
As I progressed, I pursued further studies, completing my Bachelor’s in Operations Management, Master’s in Operations Management, and a PhD in Corrosion Engineering, along with multiple technical certifications from internationally recognized bodies such as AMPP, FROSIO, PMP, and IRCLASS.
At the same time, I transitioned into inspection and technical advisory roles, supporting major oil & gas, marine, and infrastructure projects. This phase enabled me to work closely with clients, engineers, applicators, and coating manufacturers, bridging the gap between design standards and field realities.
Over time, I came to realize that corrosion management extends far beyond inspection or coatings alone. It is about developing sustainable, long-term solutions that not only protect assets but also optimize performance and significantly reduce lifecycle costs.
This vision eventually led me to establish The Anti Corrosion Experts (ACE), where I now serve as Managing Director. At ACE, we combine technical expertise with innovation to deliver complete solutions in coatings, linings, fireproofing, and corrosion mitigation. What began as my personal career journey has now grown into a platform where I can also give back—mentoring young inspectors, hosting case study discussions, and offering free guidance. I do this because I know the struggles of the early years, and I want to ensure the next generation receives the support I once wished for.
Looking back, the journey from painter and blaster to Managing Director has been both challenging and rewarding. Looking forward, my mission remains the same: to advance the science and practice of corrosion protection, and to empower the next generation of professionals to achieve even more. Throughout this journey, I have always lived by one principle: if you respect time, time will respect you. Discipline and planning have been the foundation of my growth, and I continue to believe they are the keys to long-term success.
You’ve built ACE into a highly reputable consultancy specializing in coatings, corrosion surveys, and project management. What was your vision when you started ACE, and how has it evolved over the last five years?
When I founded ACE, my vision was clear: to create a specialized consultancy that not only provided technical expertise but also delivered practical, value-driven solutions to industries struggling with corrosion challenges. Having experienced the industry from the ground up, I wanted ACE to be more than just an inspection or advisory service. My aim was to build a trusted partner that clients could rely on for coatings consultancy, corrosion surveys, and project management, with a strong focus on quality, safety, and compliance.
Over the last five years, that vision has matured significantly. What started as a niche consultancy has now evolved into a comprehensive service provider, offering end-to-end solutions from material selection and specification review to inspection, failure analysis, and lifecycle asset management. We have expanded our scope to include advanced technologies, training programs, and mentoring initiatives, ensuring that both clients and young professionals benefit from our expertise.
The journey has been one of growth, learning, and adaptation. Today, ACE is recognized not only for its technical excellence but also for its ability to integrate innovation, sustainability, and cost-effectiveness into every project. My original vision remains intact, but it has been enriched by experience, partnerships, and the trust we’ve built with our clients.
ACE has worked with prestigious clients like ARAMCO, NPCC, and Technip. From your experience, what are the most common challenges clients face in anti-corrosion strategies, and how does ACE help them overcome these?
Working with esteemed clients such as ARAMCO, NPCC, and Technip has given us deep insight into the recurring challenges organizations face when implementing anti-corrosion strategies. The most common issues include:
- Inadequate surface preparation and coating application: Even the best coating system will fail if the fundamentals are not executed correctly.
- Misalignment between design and field execution: Often, specifications look perfect on paper but face practical challenges during implementation.
- Lifecycle cost management: Many clients focus on initial capital savings rather than long-term performance, leading to premature failures and costly repairs.
- Environmental and safety compliance: With increasing regulations, balancing technical solutions with HSE requirements is always a challenge.
At ACE, our approach is to bridge these gaps through a combination of technical expertise and practical experience. We begin with comprehensive corrosion surveys and root-cause analysis to ensure the solution addresses the real problem. Our team works closely with clients to align design specifications with on-site realities, ensuring surface preparation, coating application, and quality assurance are never compromised.
Moreover, we emphasize lifecycle thinking—helping clients select solutions that may require a slightly higher upfront investment but deliver significant savings in durability, maintenance, and downtime. By integrating innovation, training, and international best practices, we enable clients to achieve sustainable asset protection while meeting both technical and regulatory requirements.
Ultimately, ACE’s role is not just to solve problems but to help clients develop a proactive, long-term corrosion management strategy that extends the life of their assets and protects their investments.
Having worked hands-on as a sandblaster and painter earlier in your career, how has that practical experience shaped your leadership style and decision-making as a Managing Director today?
My early years as a sandblaster and painter shaped not only my technical foundation but also my leadership philosophy. Working on the ground taught me the realities of the job—the physical demands, the safety risks, and the importance of precision in every task. These experiences gave me a deep respect for the workforce and an appreciation for the challenges faced by applicators and inspectors alike.
As a Managing Director today, this background influences my decision-making in several ways. First, it allows me to lead with empathy. I understand the pressures at every level of a project, from the field to the boardroom, and that perspective helps me make decisions that are both practical and people-focused. Second, it has instilled in me a “no shortcuts” mindset. I know firsthand that cutting corners during preparation or application can lead to costly failures, so I encourage my teams and clients to uphold the highest standards, even if it requires more effort upfront.
Most importantly, my hands-on experience keeps me grounded. It reminds me that leadership is not about issuing directives from the top, but about guiding, supporting, and inspiring teams to deliver excellence. By blending technical know-how with practical wisdom, I strive to create a culture at ACE where safety, quality, and innovation go hand in hand.
The coatings and corrosion industry is continuously evolving with new technologies and standards. What innovations or practices do you believe are making the most impact right now?
The coatings and corrosion industry is undergoing a significant transformation, driven by innovation, sustainability, and digital integration. A few developments stand out as particularly impactful right now:
- Advanced Coating Systems: High-performance, application-friendly solutions designed to perform reliably in aggressive climate conditions—especially for GCC environments—are making a real difference. Advanced epoxy systems, high-impact environment-resistant coatings, and environmentally friendly formulations are extending asset service life while minimizing environmental impact. These innovations are shifting the industry’s focus from short-term protection to long-term asset sustainability.
- Digitalization and Remote Monitoring: The adoption of digital inspection tools, drones, and moisture or corrosion sensors is revolutionizing how we assess and manage assets. Real-time data collection enables predictive maintenance rather than reactive intervention, ultimately saving both time and costs.
- Stricter Standards and Sustainability Practices: With global emphasis on ESG and sustainability, standards are becoming more rigorous, pushing manufacturers and contractors to adopt safer, greener, and more durable technologies. Low-VOC and solvent-free coatings, for example, are gaining prominence across industries.
- Training and Knowledge Transfer: Technology is only as strong as the people applying it. Today, advanced training programs, virtual reality simulators, and standardized qualifications are helping ensure consistency and quality across the industry.
At ACE, we actively embrace these innovations by combining cutting-edge materials with digital tools, while also mentoring the next generation of inspectors and engineers. The industry is moving toward a future where coatings are smarter, projects are more sustainable, and corrosion management is seen as an integral part of asset lifecycle planning rather than just a maintenance activity.
Corrosion often leads to significant financial and safety risks for oil & gas and marine industries. What role do you see advanced inspection methods and NDT playing in mitigating these risks?
Corrosion is one of the most costly and dangerous challenges in the oil & gas and marine sectors, as it directly impacts asset integrity, safety, and operational reliability. Advanced inspection methods and NDT play a critical role in reducing these risks by providing accurate, non-intrusive, and real-time insights into asset conditions.
Techniques such as ultrasonic testing, phased array, magnetic flux leakage, and digital radiography allow us to detect hidden flaws, wall-thickness reductions, and early signs of degradation long before they become critical. Combined with drones, robotics, and remote monitoring sensors, these methods enable safer inspections in hazardous or hard-to-access environments while minimizing downtime.
What’s equally important is how these technologies feed into predictive maintenance strategies. By integrating inspection data with digital platforms, we can build a complete picture of asset health, forecast failure points, and implement proactive interventions. This not only reduces the likelihood of accidents but also optimizes maintenance schedules, lowering lifecycle costs.
At ACE, we strongly advocate for combining advanced NDT with traditional corrosion management practices. This hybrid approach ensures that our clients gain the best of both worlds—practical field experience supported by cutting-edge technology. Ultimately, the role of advanced inspection methods is to move the industry from reactive repairs to predictive and preventive solutions, safeguarding both people and assets.
During your time as an advisor and inspector, you’ve been directly involved in warranty projects and failure investigations. Could you share a challenging project where your team’s expertise made a major difference in solving the issue?
One particularly challenging project I was involved in concerned coating failures within water ballast tanks (WBTs) of a marine vessel that had been subjected to repeated tug-induced impact stress during berthing. The client was facing warranty claims after premature blistering, cracking, and underfilm corrosion appeared within just a few years of service.
Our investigation applied a structured failure analysis approach. Field inspections, adhesion pull-off testing (ASTM D4541), Bresle salt testing (ISO 8502-6/9), ultrasonic thickness (UT) surveys, and ISO 4628 visual classifications were performed. The results revealed multiple degradation modes: adhesive delamination (ISO 4628-5), cohesive cracking (ISO 4628-4), and underfilm corrosion (ISO 4628-3), particularly concentrated around stiffener toes, weld heat-affected zones, and impact-prone shell plating. Elevated dry film thickness (DFT) in spot-repaired zones—sometimes exceeding four times the specified limit—had created brittle, stress-prone layers that failed under cyclic flexure.
This work closely aligned with the findings I later published in my research paper “Failure Analysis of Surface-Tolerant Epoxy Coating System in Water Ballast Tanks Subjected to Tug-Induced Impact Damage Stress” (IJSRED, 2025). In that study, I demonstrated how mechanical deformation from tugboat impacts, compounded by excessive DFT and marginal surface preparation (St 2/St 3 per ISO 8501-1), directly accelerated coating breakdown and underfilm corrosion.
In practice, our remediation strategy involved selective abrasive blasting to Sa 2½ in accordance with ISO 8501-1, followed by strict dry film thickness control in line with ISO 19840 and SSPC-PA 2. We specified the application of a high-build, flexible epoxy barrier system engineered to withstand cyclic mechanical stresses, ensuring complete film integrity with no defects or holidays. In parallel, we reinforced QA/QC protocols by mandating soluble salt testing (ISO 8502-6/9), implementing edge stripe coating, and engaging independent AMPP/FROSIO-certified inspectors to verify compliance at every stage.
The outcome restored long-term integrity while avoiding unnecessary full-scale recoating. More importantly, the project highlighted the critical importance of integrating mechanical stress considerations into coating design and maintenance, not just chemical and environmental factors. By linking practical failure investigation with published research, my team was able to deliver a solution that improved standards and informed future specifications for the client.
At OMCORR25, you contributed as a speaker. Looking back, what were your key takeaways from the event, and how do you think such platforms help industry professionals move forward?
OMCORR25 was a milestone event for me personally and professionally. My session focused on rudder and appendage protection through the use of glass flake epoxy (GFE) primers, a subject I also published in the International Journal of Scientific Research and Engineering Development (2025). Drawing from a dataset of 125 vessel inspections and long-term field performance on LNG carriers, I demonstrated how a 300 µm GFE barrier system reduced pitting rates by almost 90%, extended repaint intervals, and delivered 50–60% lifecycle cost savings compared with conventional epoxies. Sharing this research on an international platform reinforced the importance of engineering coatings for dual-mode protection against both cavitation erosion and electrochemical attack.
Another major takeaway was the emergence of AI and digitalization as key drivers of the industry. Presentations showed how predictive analytics, digital twins, and sensor-based monitoring can forecast degradation and optimize maintenance. When combined with advanced coatings, AI allows us to move away from reactive maintenance toward fully predictive asset integrity management.
I was particularly impressed by the recent innovations from coating manufacturers, notably Jotun’s Covallox technology presented by Mr. Bierbal Singh Bhandari (Regional Director of Technical Support). This advancement highlights how material science is progressing toward the development of barrier systems that offer enhanced resilience, superior flexibility, and improved environmental compatibility while also delivering cost efficiency. Such breakthroughs represent a significant step forward in aligning protective coatings with the industry’s increasing demand for smarter, sustainable, and performance-driven solutions.
Most importantly, OMCORR highlighted the power of collaboration. Operators, EPCs, paint companies, and researchers came together to share data, debate standards, and mentor young professionals. For me, the event confirmed that the future of corrosion protection lies in combining field-proven systems like glass flake epoxies, manufacturer-led innovations like Covallox, and AI-driven monitoring tools into a unified, intelligent corrosion management strategy.
As someone with both technical and managerial expertise, how do you balance delivering on the technical requirements of projects while also managing client expectations and business growth?
For me, the balance between technical delivery, client expectations, and business growth lies in making sure that solid engineering always translates into practical value.
On the technical side, I make sure projects follow international standards like ISO, NORSOK, SSPC, ASTM, and IMO PSPC, with rigorous QA/QC built in. That ensures every solution we provide is technically sound and credible.
But what matters most to clients is results. A recent example is from my published investigation on LNG carrier marine condenser vent pipelines, where we discovered microbiologically influenced corrosion (MIC) and biofouling had caused up to 85% wall thinning. Instead of just documenting the issue, I carried out a detailed root cause analysis and submitted a full case study with recommendations—material upgrades, protective epoxy linings, optimized biocide dosing, and improved filtration.
The shipowner was extremely satisfied with the findings, and most importantly, they agreed to implement the recommendations across their entire fleet, including all upcoming newbuild vessels. That not only solved the immediate problem but also created significant long-term cost savings by preventing repeat failures and reducing downtime.
This is how I approach every project: as a technical professional, I don’t stop at theory—I make sure my investigations lead to real, implementable solutions. And as a business leader, I focus on aligning those solutions with client priorities, building trust, and showing measurable value.
In short, my philosophy is clear: do the investigation properly, deliver practical solutions, and prove their worth by saving the client money and improving performance. That’s what drives client satisfaction and long-term business growth.
Sustainability and environmental responsibility are now integral to industrial operations. How do anti-corrosion strategies and coating technologies contribute to greener, more sustainable practices?
Sustainability is no longer an optional consideration—it is at the core of how industries must operate. In this context, anti-corrosion strategies and coating technologies make a direct contribution to greener, more sustainable practices.
Firstly, extending asset life is the most powerful sustainability measure. By preventing premature failures, coatings reduce the need for early steel replacement, cutting down on raw material extraction, energy-intensive manufacturing, and transport. Every year of extended service life translates into significant reductions in embodied carbon and waste.
Secondly, the industry is shifting toward eco-friendly formulations. Low-VOC, solvent-free, and waterborne coatings are replacing traditional high-solvent systems, reducing harmful emissions and improving worker safety. Advanced chemistries like Jotun’s Covallox innovation show how manufacturers are engineering products that deliver durability (up to 30 years) with a lower environmental footprint.
Thirdly, coatings play a role in energy efficiency. Fouling-resistant and smooth-surface marine coatings reduce drag, lowering fuel consumption and greenhouse gas emissions. Thermal barrier coatings and insulating systems also minimize heat loss, reducing energy demand in industrial facilities.
Finally, sustainability comes from smarter maintenance strategies. By integrating coatings with predictive monitoring and AI-driven corrosion assessments, industries can move from reactive to proactive asset management. This minimizes unplanned interventions, reduces waste from unnecessary recoating, and ensures resources are used efficiently.
At ACE, we embrace these principles by recommending coating systems that not only meet technical specifications but also support clients’ ESG goals. For us, anti-corrosion strategies are not just about asset protection—they are about contributing to a more sustainable, cost-efficient, and environmentally responsible future.
You have worked across multiple geographies and industries—from protective coatings to large-scale oil & gas projects. How do regional differences influence corrosion management strategies?
Having worked across multiple geographies, I’ve seen that corrosion management is heavily shaped by local conditions.
In the GCC, the challenges are high salinity, extreme heat, dust storms, and long humidity cycles. Coatings must combine barrier strength with UV stability and tolerance to surface contamination. In the North Sea, immersion and harsh mechanical loads make systems like NORSOK M-501 essential. In tropical Asia, monsoon-driven wet/dry cycles and microbial growth increase the risk of MIC, which requires specialized linings and biocide programs. In arctic and cold regions, coatings need flexibility and reliable curing at low temperatures within short weather windows.
These regional differences prove that corrosion strategies must always be customized. At the same time, climate change is creating an additional layer of complexity. Across the GCC, we are already seeing higher average temperatures, more intense rainfall, prolonged high-humidity cycles, and increasing airborne salinity. These changes are altering how coatings degrade and how long they last. This is the focus of my upcoming research paper, “Climate Change Impacts on Protective and Marine Coatings in the GCC Region.” In this work, I am correlating climatic trends such as rising heat, dust and sandstorms, and saline aerosol deposition with coating failure mechanisms, and exploring how protective systems will need to adapt.
While I won’t go into the conclusions here, the aim of this study is to provide a climate-adapted framework that supports industries in preparing for the environmental challenges of tomorrow.
In short, regional differences drive today’s corrosion management strategies, but climate change will be one of the defining factors shaping how we design and maintain protective systems in the future.
Beyond your professional work, what are some personal interests or hobbies that help you maintain balance and bring fresh perspectives into your leadership role?
Outside of my professional responsibilities, I find balance and inspiration in a few passions that also influence how I lead.
I spend time with a small circle of close friends and mentors whose guidance keeps me grounded. Meeting senior technical experts from different parts of the world also gives me the chance to exchange ideas and gain fresh perspectives that I can bring into my work.
Travel is another source of learning. Whenever I visit a new country, I make it a point to observe not only the culture but also the climate conditions and how they affect corrosion and coatings in real-world settings. These observations often inspire new insights and help me connect global challenges with local solutions.
One area very close to my heart is supporting young inspectors and engineers. I lead a large group of young professionals where I regularly conduct free technical classes, case study discussions, and career guidance sessions. I do this because I remember the challenges I faced early in my career, when structured mentorship and accessible technical advice were not easily available. Sharing my knowledge and helping the next generation grow gives me real satisfaction and ensures that our industry has strong, capable leaders for the future.
In short, my personal interests—whether learning from mentors, traveling, or guiding young inspectors—help me maintain balance, broaden my perspective, and keep me connected to both the present and future of our industry.
Finally, Dr. Vijesh, how do you view platforms like OnestopNDT? Do you see them as valuable for professionals in the coatings and corrosion sector to share knowledge, build networks, and stay updated on the latest in NDT and related fields?
I see platforms like OnestopNDT as extremely valuable for our industry. In today’s fast-changing environment, knowledge sharing and collaboration are just as important as technical expertise.
For professionals in the coatings and corrosion sector, such platforms provide three key benefits. First, they create a knowledge hub where case studies, expert opinions, and technical insights are easily accessible to a global audience. Second, they enable network building, connecting young inspectors, experienced specialists, manufacturers, and asset owners on a single platform. This kind of networking is critical for career growth, mentorship, and collaboration across industries and geographies. Third, they keep us updated on innovations—from advanced coatings and NDT technologies to digital tools and sustainability-driven practices.
Personally, I believe platforms like OnestopNDT also play an important role in supporting the next generation of inspectors and engineers. By giving them access to expert discussions, technical interviews, and global best practices, they help bridge the gap I myself struggled with in the early stages of my career.
In short, OnestopNDT is more than just an information platform—it’s a community that fosters growth, innovation, and professional excellence. For those of us in corrosion and coatings, it provides the visibility, collaboration, and continuous learning we need to stay ahead in this evolving field.
Through this insightful conversation, Dr. Vijesh Vijayan’s journey shows how discipline, vision, and innovation can turn challenges into opportunities. His persistence and commitment to empowering the next generation promise a stronger, more sustainable future for the coatings and corrosion industry.
