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Why coatings fail

I believe that all coating failures can be grouped into 1 (or maybe even more) of 3 categories.

 

  • Material Selection
  • Surface Preparation
  • Application
Material Selection: When working with your local coatings expert, this should rarely happen.  They should ask you at a minimum these questions:
  • How long has it taken to get in the condition it is in?
  • What do you believe caused it?
  • What is the operating temperature?
  • What if any chemicals are present?
  • How long can the equipment be out of service?
Without at least questions answered the proper coating selection can be a gamble.
Surface Preparation: This is where I see the most failures.  The applicator is either in a rush, the customer is pushing to get back online, or they just plum don't know the importance of the proper surface preparation.  The coatings consultant you are working with should take the time to work with and train who ever is doing the surface preparation.  The best material in the world won't work properly with poor surface prep. Take time to do this step right, or make sure you have time to redo the application.
Application: This area includes the mixing and actual application of the material.  Many coatings come as 2 part components are those two parts are typically different colors which makes it easy to mix.  Not "wetting" out the substrate is one area I see problems.  In order to achieve the best bond the coating must have good surface contact with the substrate. Taking time to put a thin coat, pressed firmly onto the surface is always a good step.
written by: David Robertson
NACE Certified Coatings Inspector (#9893)
DBR Associates, Inc. Authorized Belzona Distributor