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August 22 - August 28, 2011

In your experience, what is the most common cause of premature coating failures?

More items for Quality Control
Answers Votes
Poor workmanship 76%
Incorrect specification 12%
Unforeseen exposure condition (due to design defect, for instance) 10%
Defective coating material 2%

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Tagged categories: Coating failure

Comment from Glenn Summers, (8/25/2011, 6:36 AM)

Speaking only as it relates to concrete substrates; most specifications do not go far enough to insure that a concrete is properly treated, prior to the coating application. If a concrete is not "Stabilized" prior to coating, the Gel-Pore/Capillary system of the concrete will remain Open and Active to expell a concrete internal chemistry for years to come. Often, a specification is written to take in to account Harsh Service Environments as it relates to contaminates entering a concrete matrix from the exterior of a structure. It is one thing to attempt to protect a concrete by coating the exterior, but this type of specification falls short of a "Durable Surface". Great care and expense of sand blasting, high pressure washes and even acid etching will attempt to obtain longevity of a coating, but do not consider that an unstable concrete will allow moisture vapor to deposit chemicals underneath the best of coatings. When this internal chemistry and moisture migrates out to an atmosphere, coating failures are certain. A specification that doesn't address moisture travel In and Out of a concrete substrate will lead to a coating failure, not to mention all of the other deleterious events that occur to a concrete. When Carbonation is allowed to reduce the internal pH of a concrete below 11.5 pH, a coating loss is a minor problem compared to the corrosion cells that are now allowed to form on the reinforcing steel! At this point, "Another Coat of Paint Won't Help"!

Comment from Chuck Stevens, (8/31/2011, 12:18 PM)

It is extremely Important that the inspection attends the Pre-Job conference to discuss grey area's and how they should be addressed as agreed to by all involved

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