Coating Defect Visual Aid

What It Looks Like

Peeling, flaking, or sheets of coating separating cleanly at an interface.

Common Causes

Possible causes and contributing factors include:

• Inadequate surface preparation
• Surface contamination
• Exceeded recoat interval
• Incompatible coating layers
• Moisture at the interface

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

adhesive failure · peeling · delamination

What It Looks Like

A split through the coating film with coating material remaining on both separated surfaces.

Common Causes

Possible causes and contributing factors include:

• Low cohesive strength
• Incorrect mixing or cure
• Internal stress
• Excessive film build
• Aged or degraded coating

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

cohesive fracture · film rupture

What It Looks Like

One coating layer lifts or peels from the coat beneath while the lower layer remains attached.

Common Causes

Possible causes and contributing factors include:

• Exceeded recoat window
• Amine blush or contamination
• Glossy or inadequately abraded surface
• Incompatible coats
• Condensation between coats

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

intercoat adhesion · peeling

What It Looks Like

Discrete rounded swellings that may contain liquid, gas, corrosion products, or remain dry.

Common Causes

Possible causes and contributing factors include:

• Moisture
• Soluble contamination
• Osmotic pressure
• Solvent entrapment
• Loss of adhesion

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

bubbles · blisters

What It Looks Like

Often numerous fluid-filled blisters in immersed or persistently wet service.

Common Causes

Possible causes and contributing factors include:

• Soluble salts beneath coating
• Water permeation
• Contaminated substrate or abrasive
• Entrapped water-soluble material

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

osmosis · immersed-service blistering

What It Looks Like

Localized or general red-brown rust staining, spots, or exposed corroding steel.

Common Causes

Possible causes and contributing factors include:

• Coating breakdown
• Insufficient barrier thickness
• Holidays
• Mechanical damage
• Aggressive exposure

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

rust breakthrough · corrosion · general corrosion

What It Looks Like

Fine yellow, orange, or brown discoloration developing soon after wet cleaning or preparation.

Common Causes

Possible causes and contributing factors include:

• High humidity
• Residual water
• Delayed coating application
• Contaminated rinse water
• Insufficient ventilation

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

flash rust · gingering

What It Looks Like

Rust staining, swelling, lifting, or creep extending from damage, edges, or discontinuities.

Common Causes

Possible causes and contributing factors include:

• Coating discontinuity
• Poor adhesion
• Soluble salts
• Moisture ingress
• Damage exposing substrate

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

corrosion creep · underfilm rusting

What It Looks Like

Rusting or coating breakdown tracing edges and irregular steel details.

Common Causes

Possible causes and contributing factors include:

• Poor edge rounding
• Low film build at edges
• Omitted stripe coat
• Difficult spray access
• Mechanical damage

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

edge retention · stripe coating

What It Looks Like

Fine isolated holes resembling needle pricks, sometimes visible only under magnification or holiday testing.

Common Causes

Possible causes and contributing factors include:

• Air release from porous substrate
• Incorrect application
• High-viscosity material
• Rapid solvent release
• Contamination

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

pinholes · micro-holidays

What It Looks Like

Visible misses, bare substrate, or electrically detected discontinuities.

Common Causes

Possible causes and contributing factors include:

• Poor access or lighting
• Incomplete application
• Complex geometry
• Insufficient overlap
• Damage after application

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

holiday · miss · discontinuity

What It Looks Like

Sponge-like, porous, or finely pitted film that may contain interconnected openings.

Common Causes

Possible causes and contributing factors include:

• Air entrapment
• Outgassing
• Incorrect spray setup
• Porous substrate
• Excessive atomization

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

voids · porous film

What It Looks Like

Bowl-shaped depressions, sometimes with a central contaminant or raised rim.

Common Causes

Possible causes and contributing factors include:

• Oil or silicone contamination
• Airborne contamination
• Incompatible additive
• Poor substrate wetting

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

craters · pitting

What It Looks Like

Small round depressions with a distinct rim and exposed or thin centre.

Common Causes

Possible causes and contributing factors include:

• Silicone
• Oil or grease
• Release agents
• Contaminated tools or air supply

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

fisheyes · surface tension defect

What It Looks Like

Irregular bare or thin patches bordered by heavier coating.

Common Causes

Possible causes and contributing factors include:

• Low surface energy contamination
• Incompatible underlying coat
• Excessively smooth surface
• Incorrect thinning

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

retraction · dewetting

What It Looks Like

Broad drooping waves, curtains, or thick accumulations on vertical surfaces.

Common Causes

Possible causes and contributing factors include:

• Excessive wet film thickness
• Over-thinning
• Incorrect spray technique
• Low material viscosity
• Cold substrate

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

sags · curtaining

What It Looks Like

Distinct vertical rivulets or tears extending below a heavy application point.

Common Causes

Possible causes and contributing factors include:

• Localized over-application
• Gun held too close
• Slow spray pass
• Excess thinner

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

rundown · tears

What It Looks Like

Uniform fine hills and valleys rather than a smooth level film.

Common Causes

Possible causes and contributing factors include:

• Poor atomization
• High viscosity
• Incorrect thinner
• Gun distance or pressure
• Insufficient flow and levelling

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

texture · poor levelling

What It Looks Like

Rough, powdery, grainy, or porous surface with poor cohesion or intercoat bonding.

Common Causes

Possible causes and contributing factors include:

• Excessive gun distance
• High atomizing pressure
• Hot or windy conditions
• Fast solvent
• Overspray deposition

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

dry fall · rough spray

What It Looks Like

Dusty, rough, or differently coloured deposit on nearby coated or uncoated surfaces.

Common Causes

Possible causes and contributing factors include:

• Poor masking or containment
• Wind or airflow
• Spray pattern overlap
• Work sequencing

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

spray drift · fallout

What It Looks Like

Ridges, folds, or shrivelled skin across the coating surface.

Common Causes

Possible causes and contributing factors include:

• Excessive film thickness
• Rapid surface drying
• Incompatible recoating
• Cold conditions
• Incorrect thinner

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

shrivelling · surface wrinkling

What It Looks Like

Raised, distorted, or detached underlying film following recoating.

Common Causes

Possible causes and contributing factors include:

• Strong solvent attack
• Incompatible coating
• Recoat timing
• Uncured underlying coat

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

solvent lifting · recoat attack

What It Looks Like

Pattern resembling dried mud, often extending deeply through the applied layer.

Common Causes

Possible causes and contributing factors include:

• Excessive film build
• Rapid drying
• High-build waterborne or inorganic material
• Improper application

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

alligator cracking · shrinkage cracking

What It Looks Like

Dense network of short hairline surface cracks.

Common Causes

Possible causes and contributing factors include:

• Aging and embrittlement
• UV exposure
• Thermal cycling
• Internal stress

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

surface checking · crazing

What It Looks Like

Linear or branched fractures ranging from isolated cracks to broad networks.

Common Causes

Possible causes and contributing factors include:

• Embrittlement
• Excessive film thickness
• Substrate movement
• Thermal stress
• Incompatible layers

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

splitting · fracture

What It Looks Like

Powder transfers to a hand or cloth and colour appears lighter or duller.

Common Causes

Possible causes and contributing factors include:

• UV degradation
• Weathering
• Unsuitable topcoat for exposure
• Aging

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

powdering · binder degradation

What It Looks Like

Reduced colour intensity or uneven colour compared with protected areas.

Common Causes

Possible causes and contributing factors include:

• UV exposure
• Pigment instability
• Chemical exposure
• Uneven weathering

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

colour loss · lightening

What It Looks Like

Darkening, yellowing, staining, mottling, or inconsistent colour.

Common Causes

Possible causes and contributing factors include:

• Chemical exposure
• Heat
• Contamination
• Uneven cure
• Batch or mixing variation

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

staining · yellowing · colour variation

What It Looks Like

Cloudy, milky, or dull surface film, often after humid or cool application.

Common Causes

Possible causes and contributing factors include:

• High humidity
• Condensation
• Low temperature
• Moisture during cure
• Solvent imbalance

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

blushing · haze

What It Looks Like

Clear, whitish, greasy, or wax-like deposit; surface may feel slick or appear dull.

Common Causes

Possible causes and contributing factors include:

• Moisture and carbon dioxide during cure
• Cool humid conditions
• Epoxy chemistry and cure state

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

carbamation · epoxy blush

What It Looks Like

Soft film, blistering, poor cure, odour, or later bubbling and loss of adhesion.

Common Causes

Possible causes and contributing factors include:

• Excessive film thickness
• Short flash time
• Fast overcoating
• Low ventilation
• Incorrect thinner

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

retained solvent · soft film

What It Looks Like

Numerous small rounded pits, bubbles, or burst openings in the surface.

Common Causes

Possible causes and contributing factors include:

• Rapid solvent release
• Excessive wet film
• High temperature
• Insufficient flash time
• Incorrect thinner

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

popping · solvent boil

What It Looks Like

Raised bubbles in wet or cured film; some may burst and leave craters.

Common Causes

Possible causes and contributing factors include:

• Outgassing
• Entrained air
• Moisture
• Heat
• Solvent release

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

bubbles · outgassing

What It Looks Like

Frothy wet coating or cured film containing many small bubbles and voids.

Common Causes

Possible causes and contributing factors include:

• High-speed mixing
• Air entrainment
• Incorrect roller
• Porous substrate
• Material formulation or temperature

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

entrained air · foam

What It Looks Like

Retraction, beading, skips, thin patches, or failure to flow over the surface.

Common Causes

Possible causes and contributing factors include:

• Oil, grease, or silicone
• High surface tension
• Dust
• Incompatible surface
• Incorrect viscosity

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

dewetting · beading

What It Looks Like

Visible thinness, substrate show-through, or early breakdown concentrated at edges.

Common Causes

Possible causes and contributing factors include:

• Surface tension pull-back
• Sharp edges
• Omitted stripe coat
• Poor access
• Inadequate application technique

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

edge retention · thin edges

What It Looks Like

May appear visually acceptable; thin or translucent areas can occur at edges and complex geometry.

Common Causes

Possible causes and contributing factors include:

• Insufficient wet film
• Excess thinning
• Poor coverage control
• High profile allowance
• Measurement or calibration issue

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

under-thickness · insufficient film build

What It Looks Like

Heavy build, sags, cracking, slow cure, or an otherwise normal-looking film confirmed by measurement.

Common Causes

Possible causes and contributing factors include:

• Over-application
• Incorrect wet-film control
• Excess passes
• Geometry-related accumulation

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

over-thickness · high film build

What It Looks Like

Patchy appearance or inconsistent readings, often around geometry, overlaps, and access limitations.

Common Causes

Possible causes and contributing factors include:

• Inconsistent spray technique
• Complex geometry
• Poor lighting or access
• Uneven surface profile
• Inadequate wet-film control

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

variable thickness · non-uniform film

What It Looks Like

Adhesion loss, cratering, blistering, staining, inclusions, or localized early breakdown.

Common Causes

Possible causes and contributing factors include:

• Oil, salts, dust, moisture, silicone, chemicals, or process residues
• Contaminated tools or air supply

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

foreign matter · surface contamination

What It Looks Like

May not be visible initially; later blistering, osmotic activity, or underfilm corrosion may develop.

Common Causes

Possible causes and contributing factors include:

• Marine or de-icing exposure
• Contaminated abrasive or water
• Inadequate washing
• Salt redeposition

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

soluble salts · chlorides · conductivity

What It Looks Like

Fish eyes, crawling, adhesion loss, dark staining, or visibly greasy areas.

Common Causes

Possible causes and contributing factors include:

• Leaking equipment
• Handling
• Compressed-air contamination
• Inadequate degreasing

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

hydrocarbon contamination · degreasing

What It Looks Like

Raised specks, roughness, nibs, or visible particulate embedded at the surface.

Common Causes

Possible causes and contributing factors include:

• Poor cleaning
• Airborne dust
• Nearby blasting
• Dirty equipment or clothing
• Inadequate enclosure control

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

dust nibs · particulate inclusion

What It Looks Like

Visible grit, irregular protrusions, rough inclusions, or contamination concentrated in pockets.

Common Causes

Possible causes and contributing factors include:

• Excessive blasting pressure
• Soft steel or abrasive
• Poor blowdown or vacuuming
• Complex geometry

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

retained grit · abrasive embedment

What It Looks Like

Peak rusting, incomplete peak coverage, adhesion loss, or excessive coating demand.

Common Causes

Possible causes and contributing factors include:

• Profile too high or too low
• Incorrect abrasive
• Inconsistent blasting
• Insufficient coating over profile peaks

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

anchor pattern · peak coverage · profile depth

What It Looks Like

Early spot, edge, weld, or general rusting after application or return to service.

Common Causes

Possible causes and contributing factors include:

• Preparation deficiency
• Low DFT
• Holidays
• Contamination
• Unsuitable system or severe exposure
• Application defect

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

early rusting · premature breakdown

What It Looks Like

Discrete scratches, gouges, chips, worn areas, or exposed substrate following physical contact.

Common Causes

Possible causes and contributing factors include:

• Lifting and rigging
• Erection
• Tools and equipment
• Impact
• Maintenance activity

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

handling damage · coating damage

What It Looks Like

Chip, dent, star fracture, crushed film, or exposed substrate at the impact point.

Common Causes

Possible causes and contributing factors include:

• Dropped objects
• Collision
• Tool strike
• Debris impact

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

chip · impact fracture

What It Looks Like

Polished, thinned, scratched, or worn-through tracks aligned with contact or flow.

Common Causes

Possible causes and contributing factors include:

• Cargo or equipment contact
• Slurry or particle flow
• Fenders or ropes
• Cleaning activity

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

wear · erosion · rubbing

What It Looks Like

Chalking, fading, loss of gloss, embrittlement, checking, or surface erosion.

Common Causes

Possible causes and contributing factors include:

• Ultraviolet exposure
• Unsuitable resin for exterior service
• Long-term weathering

Inspection Considerations

• Photograph the defect and record its location, extent, and distribution before destructive examination.
• Review the coating system, application history, environmental records, and surrounding film thickness.
• Confirm substrate and intercoat condition through inspection and testing where required.

Typical Remediation

Remove affected coating to a sound, well-adhered boundary. Confirm and correct the contributing condition before preparing the surface and rebuilding the specified coating system.

Prevention

Follow the approved specification, product Technical Data Sheet, environmental limits, preparation requirements, and inspection plan.

Related Terms

photo-oxidation · weathering