F-Files: Mechanisms of Failure
Saponification: from paint to the grave

From JPCL, May 2014

by E. Bud Senkowski, P.E., PCS, KTA-Tator, Inc., Richard A. Burgess, PCS, KTA-Tator, Inc., Series Editor

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Tagged categories: Coating failure; Coating Materials; Failure analysis; KTA-Tator; Saponification

Comment from Gene Kube, (7/17/2014, 3:35 PM)

Excellent article. Well written and very informative


Comment from Steven Frisk, (7/19/2014, 12:57 AM)

Thanks E.Bud.As a painter I need answers to failed coatings.Why, why,why? Everything peels off! Not sure I have answer yet but am smarter today.


Comment from Alfredo Claussen, (7/22/2014, 11:36 AM)

Good article. This is the kind of articles we need most. Thanks.


Comment from Manoj Nipane, (8/4/2014, 7:42 AM)

Thanks for sharing........


Comment from Gustavo Lopez, (8/12/2014, 10:52 AM)

Thanks for this articles


Comment from Ken Morgan, (8/13/2014, 10:26 AM)

Thanks for the well written and informative article. The case history example was particularly interesting.


Comment from Kevin OMalley, (8/14/2014, 12:37 PM)

Good article describing a common problem that I have seen many times to galvanized metal surfaces. However, your example Of the epoxy ester coating suggests that all dryfall type epoxy ester coatings are subject to the potential for saponification and I know from many years experience that PPG and Devoe Coatings manufacture and market an epoxy ester dryfall coating primarily for galvanized metal and are not subject to this type of reaction. My point is that I do not believe that all epoxy ester dryfall type coatings, rather maybe some that are produced with alkyd type resins, might be. Would you agree?


Comment from Bud Senkowski, (8/15/2014, 2:27 PM)

Thank you for your persceptive comment. Saponification could be an issue only with dry-fall coatings that contain an epoxy ester-modified alkyd. Other dry-fall coatings would be safe to use.


Comment from Eduardo Garrido, (10/2/2014, 4:45 PM)

Excellent article. What does dry-fall coating mean?


Comment from David Zuskin, (10/6/2014, 7:34 AM)

A dry fall coating is a coating that when sprayed (typically on an overhead, a ceiling)dries to dust before landing and does not adhere to surfaces below the ceiling


Comment from Bud Senkowski, (10/6/2014, 9:39 AM)

Dry fall (sometimes called dry fog) coatings produce overspray that dries to finely-divided solid particles before it reaches the floor or travels more than approximately 10'. Since there is no wet residue reaching the floor, There is no wet residue reaching or drying at floor level, it is easy to clean up.


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