Understanding the Consequences of Coating Failures
Industrial coatings may be referred to as complex combinations of different raw materials mixed, applied, dried, and cured in the right manner to deliver optimum performance. These coatings are used in diverse environmental conditions and are expected to retain their integrity and protect the substrates from the devastating effects of heat, wind, sunlight, rain, humidity, abrasion, corrosion, etc. It is not surprising for industrial coatings to exhibit premature failure or defects that may lead to failures in the future. Coating defects and failures can manifest themselves at different phases throughout the coating life.
For a better understanding of coating failures and their consequences, it is important to discuss some of the most common types of failures.
Coating Failure Explained
The primary function of protective coatings is to protect industrial structures from corrosion and deterioration caused in the absence or failure of a protective coating. Such failures can take place because of disappearance or reduction of the bond between the surface and coats. As a result, the substrate gets exposed to unfavourable conditions as the coating is not able to fulfil its function.
Some common examples of coating failure are
Curing related failures: These failures result from not adding the cure, not adding the right amount of cure, or adding the wrong cure.
Adhesion related failures: These defects are caused by the loss of adhesion between the layers of coating or the substrate resulting from
- Contamination of the coating application surface
- Wrong or insufficient surface preparation
- Application of coatings that are incompatible
- Exceeding topcoat window
- Application of coating to a glossy surface
Weld Failures: Rust is a common cause of in-service coating failure that starts at a rough spattered weld seam or sharp edge. This happens because as the wet coats dry and the solvent are released, the coating starts to shrink. As a result, only a thin layer of the coat remains at the top or peak.
Consequences of Coating Failure
Safety and cost are two serious consequences of a coating failure. All types of protective coatings safeguard industrial machineries, structures, and systems from corrosion. Failure of the coating over a period of time may have a serious impact on public safety by damaging
- Public infrastructure such as rail, highway, bridges, amusement park, etc
- Utility structures such as storage tanks, water treatment plants, etc
- Pipeline structures for water, wastewater, chemicals, oil and gas, etc
Also, structures damaged by corrosion are likely to cause
- Release of toxic gases or fluids that are harmful to the environment, people and wildlife
- Contamination in food and beverage industries
- Broken equipment, crashed planes, sinking vessels, and much more.
From the cost perspective, it is far more expensive to repair and recoat rusted steel compared to the initial cost for protecting the same surface from corrosion. In addition to this, coating failure also leads to expenses such as
- Loss of revenue because of downtime
- Cost of material
- Potential lawsuits
- Increased fabrication cost for steel substrate preparation.
One of the most effective ways to avoid coating failures is to carry out thorough inspection of all your industrial coatings. To have your facility inspected by certified NACE CIP coating inspectors, please contact us at Coating Management Solutions.