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Coating Defects and Failures

Presented by: Sarah Olthof


Topics

Consequences of coating failure

Role of coatings inspector in failure avoidance

Common coating failures and defects
Scope

This webinar describes the consequences of
coating failures, field and laboratory
investigative processes undertaken to diagnose
coating failures, and reviews common coating
defects and failures.
Learning Outcomes

At the end of this unit, the student will be able
to:
– Recognize the consequences of coating failures
– Describe the coating inspector’s role in preventing
failures
– Identify common coating failures and defects seen
in the field
Protective Coatings

Principal material used for corrosion
protection

All coatings will breakdown over time

Service life can be extended by performing
maintenance painting once deterioration is
identified
Premature Coating Failure

Failures that occur before the anticipated
service life ends can be caused by:
– Improper surface preparation
– Improper coating application procedures
– Improper coating system selection
– Improper formulation
– Poor quality raw materials
Once Premature Failure
Occurs…

The investigation begins…….
– What was the cause of the premature coating
failure?
– What party was responsible for the failure?
– What level of repair is required to ensure corrosion
protection and integrity of the structure is
acceptable?
Consequences of Coating
Failures

Financial impacts

Litigation

Substrate repair or replacement

Costly rework and downtime
Substrate Repair or
Replacement

When a failure occurs, the substrate is
exposed to the environment until the defect
is detected

Unprotected substrate is susceptible to
corrosion and possible section loss

Integrity of structure could be compromised
if coating failure is not detected for an
extended period of time

Cost to repair substrate adds to the cost of
Rework and Downtime

Remobilization, surface preparation, coating
application, and inspection of the repair or
rework can be time consuming and costly.

Hard to determine extent of rework needed.
– Does the failure indicate total removal?
– Can we get away with a spot repair?
Role of a Coating Inspector

The inspector can play a key role in helping to
prevent premature coating failure.

Qualified inspection personnel can
significantly reduce the opportunity for failure
Identification of a
Non-Conformance

The inspector:
– Identifies deficiencies as they arise
– Will work with contractor for reaction plan once
non-conformance is identified
Common Coating Defects and
Failures
Delamination

Results from loss of
adhesion between the
substrate and coating
OR between coats.
Delamination

Common Causes •
Remediation
• Poor surface • Area with poor
preparation adhesion must be
completely removed
• Intercoat cleanliness
and the cause should
• Exceeding be evaluated before
overcoating times recoating.
• Incompatibility of
topcoat and primer
Delamination

Common Causes •
Remediation
• Poor surface • Area with poor
preparation adhesion must be
completely removed
• Intercoat cleanliness
and the cause should
• Exceeding be evaluated before
overcoating times recoating.
• Incompatibility of
topcoat and primer
Blistering

Coating lifting from
the underlying
substrate
Blistering

Common Causes •
Remediation
• Contamination on the • Ensure correct
substrate surface preparation

Oils and greases and application

Soluble Salts • Soluble salt testing
(osmotic blistering)
• Solvent entrapment
Blush


Haze or oily residue
on the surface of a
coating
Blush

Common Causes •
Remediation
• High humidity or • Blush will effect
cold temperatures adhesion of topcoat
during application • If blush is detected
• Curing stages of an (not easy to detect) it
epoxy is best practice to
consult with product
• Intensified by cool
manufacturer on
temperatures and
removal tactics
increased coating
thickness
Sags/Runs


Downward
movement of paint
soon after
application on
vertical surfaces
Sags/Runs

Common Causes •
Remediation
• Over application • While wet, sags/runs
should be smoothed
• Excessive thinning
with a paint brush
• Poor workmanship
• If dry, abrade, clean,
and apply spot coat
Orange Peel

Pocked appearance;
surface of paint film
resembles the skin of
an orange
Orange Peel

Common Causes •
Remediation
• Poor application • Abrade
techniques • Clean
• Incorrect solvent • Recoat
blend
Pinholes

Formation of tiny
holes in wet paint
film during
application and
drying due to air/gas
bubbles, which burst.
The bursting bubbles
form small craters or
holes, which fail to
coalesce before the
Holidays

Similar to pinholes
(used
interchangeably)

Described as skips or
misses in the coating
system

Checked with
holiday detector
(right)
Holidays

Common Causes •
Remediation
• Difficult application • Abrade
due to equipment • Clean
access
• Recoat
• Poor workmanship
Fisheyes


Small crater-like
openings that form
during application or
shortly after
Fisheyes

Common Causes •
Remediation
• Poor surface • Abrade
preparation • Clean
• Contamination • Solvent cleaning
• Use of a thinner • Recoat
instead of solvent
cleaner
Wrinkling

Wavy lines that
appear in the paint
film during different
stages of coating
application
Wrinkling

Common Causes •
Remediation
• Excessive application • Abrade
of paint • Clean
• Actual temperatures • Recoat
exceeding or going
below application
range
• Overcoating before
previous coat has
sufficiently hardened
Dry Spray

A rough or uneven
finish in the paint
film, were particles
are not fluid and
flowing together
Dry Spray

Common Causes •
Remediation
• Improper application • Ensure proper
technique distance of the spray
gun to the substrate is
• Actual temperatures
being achieved
exceeding application
range
Summary

There are many reasons why coatings may fail.
The inspector investigates and identifies the
cause of coating failure so that it can be
remediated
QUESTIONS???

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