Coating Defect
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DILIP VELHALCoating Defect
Uploaded by
DILIP VELHALCoating 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???
