Professional Documents
Culture Documents
Coating Defects Webinar JLA
Coating Defects Webinar JLA
• 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 the coating
failure
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 adhesion
preparation must be completely
• Intercoat cleanliness removed and the cause
• Exceeding overcoating should be evaluated
times before recoating.
• Incompatibility of
topcoat and primer
Blistering
• Coating lifting from the
underlying substrate
Blistering
• Common Causes • Remediation
• Contamination on the • Ensure correct surface
substrate preparation and
• Oils and greases application
• Soluble Salts (osmotic • Soluble salt testing
blistering)
• Solvent entrapment
Blush
• Downward movement
of paint soon after
application on vertical
surfaces
Sags/Runs
• Common Causes • Remediation
• Over application • While wet, sags/runs
• Excessive thinning should be smoothed with
• Poor workmanship a paint brush
• 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 blend • Recoat
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 film dries.
Pinholes
• Common Causes • Remediation
• Solvent or air • Abrade
entrapment • Clean
• Incorrect spray • Recoat
application
• Incorrect solvent blend
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 due • Abrade
to equipment access • Clean
• Poor workmanship • Recoat
Fisheyes
• Small crater-like
openings that form
during application or
shortly after
Fisheyes
• Common Causes • Remediation
• Poor surface preparation • Abrade
• Contamination • Clean
• Use of a thinner instead • Solvent cleaning
of solvent cleaner • Recoat
Wrinkling
• Wavy lines that appear
in the paint film during
different stages of
coating application
Wrinkling
• Common Causes • Remediation
• Excessive application of • Abrade
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 distance
technique of the spray gun to the
• Actual temperatures substrate is being
exceeding application achieved
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???