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An accurate and comprehensive coating failure analysis often hinges not only on the quality of the field investigation and the laboratory analysis but also on effective communication between the field analyst and the forensic laboratory. Several steps can be taken during a field investigation to ensure that samples of coating removed for laboratory analysis fairly represent the condition of the coatings and give the forensic laboratory the best possible chance of discovering the root cause of the coating failure.
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The installation of protective coating systems must be accomplished in a manner that will avoid adverse electrolytic coupling between dissimilar metals in water tanks, process equipment, and even some atmospheric applications where condensing humidity and rainwater provide the aqueous medium for electrolytes. This paper discusses several examples of premature coating and structural failures resulting from the mixing of dissimilar metal types in systems where the anode and cathode areas are not optimized by design or engineering controls.
HISTORICAL DOCUMENT. Nonvisible surface contamination (NVSC). Impact & removal. NVSC is any substance affecting coating performance that does not leave a visible trace on a bare or previously coated carbon steel surface.
HISTORICAL DOCUMENT. Test for the presence of surface soluble salts before application of a coating system. Previously coated or eplacement substrates only. Does not include allowable limits of soluble salts.
Asset owners, engineers, consultants, coating contractors, inspectors, and others are specifying allowable levels of surface soluble salts to prevent premature coating failures. The purpose of this standard is to provide guidance about the number of and locations for soluble salt tests on steel surfaces.
This standard establishes siting and frequency requirements for soluble salt testing before the application of a subsequent coating system to previously coated substrates and replacement substrate material. It does not include allowable limits of soluble salts, which are typically addressed by the procurement documents or the coating manufacturer’s documentation.
The tank painting process for the interior of a petroleum and/or water storage tank requires proper coating selection, product application and inspection in order to achieve long-term service life. The primary cause of early coating failures in a painting project is often related to an application issue. The use of coating systems and linings formulated with Optically Active Pigments (OAP) can help to ensure correct application and inspection of the tank linings.
Painted aluminum extrusions are a common architectural material used in the manufacture of windows and door frames. The applied coatings, typically in a shop atmosphere, may not always work once installed in the field due to a variety of fabrication defects and or exposures.
Every year millions of dollars are spent litigating the responsibility issues associated with the repair or replacement of coated products that have prematurely lost their decorative or protective value due to improper coating specification or application. Many of these failures could have been avoided if the proper finishing materials and methods were specified, followed, certified and documented.
Pre-construction Primer (PCP) is a zinc-containing, weld-through primer applied at low thickness to minimize rusting of steel during storage and fabrication. PCP removal is perceived to reduce risk of coating failure associated with painting over an aged zinc primer. PCP is retained in many commercial shipbuilding operations in order to reduce costs and provide a better performing coating system. This paper will review commercial industry practices and the guidance provided by marine coating manufacturers.
We have seen a number of concrete floor finish failures caused by moisture attack from the concrete substrate. In many instances, moisture tests were conducted prior to installing the floor covering/finish to assess the moisture content of the concrete substrate. The results of the tests suggested the concrete was dry enough to install the flooring, but failure was induced by moisture in the floor assemble.
Embarking on an exploration of intriguing coating failures, where sophisticated analytical techniques are used to dig deep within the coating, fascinating and unexpected discoveries can sometimes occur.