Category Archives: adhesion failure

Our adhesion failure series covers some of the most common failures in the painting and flooring industries.

Epoxy Coating Failure : Non-Osmotic Blistering

Non-Osmotic Bubbling

In our previous article, we took a close look at osmotic blistering and the toll it takes on coated surfaces. In this article, we’ll examine the other common mechanism of coating failure: non-osmotic bubbling.

Beyond Moisture Damage

As we previously explained, osmotic blistering arises from situations in which coated surfaces are immersed in water or subject to continual high humidity. Water, sometimes driven by temperature gradients, gets under the coating surface, vaporizes and causes the damage we call osmotic blistering. On the other hand, coating damage from causes other than osmotic blistering we call bubbling, though the results of the two are similar.

read more

PennCoat’s Paint Failure Series – Peeling Ceiling

industrial painting, commercial painting, epoxy flooring, ceiling painting
industrial painting, commercial painting, epoxy flooring, ceiling painting

Peeling of Ceiling Paints – Reasons

Painting walls are easy and can be done quickly.  But painting ceilings can be equally difficult and tricky. Ceiling painting is time consuming and can be frustrating, even for experienced painters. Even adequate time and efforts required for commercial painting, it can run into problems is painting is not done properly. In case of large buildings or warehouses, it is important to paint ceilings to create bright and clean work environment. Whether you are inviting clients to your warehouse or arranging an upcoming food inspection, it is important to have the facility presentable. Ceiling paint is a vital factor that influences appearance of any industrial facility. But, if the ceiling paint starts peeling or flaking, it can be very frustrating as it directly affects the look of your structure.

read more

PennCoat’s Paint Failure Series – Fading


Paint Fading – Causes

There are various types of industrial paint.  But typically, all these paints work in the same system: 1st coat is the primer, 2nd coat is the intermediate coat, and the 3rd coat is the top coat.  The primer has anti-corrosive pigments that helps prevent corrosion and promotes surface adhesion for next layer of paint.  A layer of intermediate coat helps to increase the thickness of the paint without applying a very thick finishing coat. Intermediate coat is optional in industrial painting, because of the large surface area. Finishing coats, can be matte or glossy, and are important for increasing the aesthetic value of the product.

read more

PennCoat, Inc – Paint Failure Series – Mildew

mildew prevention Mildew – Problem with Industrial Paints

While selecting paint for any industrial surface, there are a few factors that one needs to consider.  Your choice of paint should not depend only on colors or budget, but also the paint’s performance. From anti-corrosive paint to mildew-resistant coating, there are a variety of commercial painting products available in the market. Mildew-resistant paints are, usually, used for equipments and surfaces in areas where the environment is damp.

In industrial painting, mildew is defined as a slight discoloration in the surface of the paint that is caused by a growth of fungus. From wooden to aluminum, mildew can grow on a variety of organic and inorganic surfaces. They are visible as green, gray, brown or black spots on the surface. But, mildew is not caused by paint; it is caused by presence of moisture in the environment. Thus, most painted surfaces face problem of mildew, especially, ones that receive very less or no sunlight. Mildew can also grow if paint is applied on a contaminated surface or substrate consisting of mold. Presence of mildew also interferes with adhesion, and can lead to other paint failures too.

read more

Application Failure Series – Painting Rusty Nail Heads

rusty nail heads

Rusty Nail Head Stains – Causes and Solutions

Industrial products are exposed to a variety of chemical, environmental, and temperature conditions. This increases the risk of corrosion, wrinkling, tearing, and other paint failures.  There are several types of paint failures with various reasons for each occurrence, making it difficult to identify the reason of their cause.  From selecting the wrong paint, failures related to adhesion, excessive chemical exposure, and design of painted structure, there are several minor and major factors that can ruin a well painted surface.  One of the common forms of paint failures that can transform any surface into ugly are stains from rusty nail heads.

read more

Application Failure Series – Uneven Gloss (Flashing) in Paint

uneven glossing (flashing)

Industrial Paint Problem – Uneven Gloss

Whether you consider an industrial equipment or component of any industrial product, you will find that it has multiple layers of coating on it. From a base primer layer to top coating, every industrial component undergoes a series of steps in painting before it gets suited for use. Each layer of paint has its own specific function and adds to the durability of the product. Top coatings on products provide protective layer against corrosion, abrasion, chemical resistance and also adds to their aesthetic properties. But, if the top coat has not been applied properly, it can deteriorate the appearance of the product rather than adding to it.

read more

Application Failure Series – Paint Surface Cratering

paint failure cratering

Cratering in Paint – Why does it Occur

Painting can often be an underestimated step in securing the longevity of a plant or manufacturing facility.  Its benefits are obvious, but there is room for error during application.  And these errors and imperfections painted are typically much more difficult to remedy after the application has been installed, often leaving the only option to scrape and repaint.  Due to application failure, pepainting can be tedious and frustrating.  However if you are careful from the start, it is possible to avoid waste time and money.

read more

PennCoat, Inc – Adhesion Failure Series – Galvanized Metal

Industrial Painting - Galvanized metal - adhesion failure

Failure to properly prime galvanized metal typically results in peeling.

When received from a production mill, galvanized metal is very alkaline.  Additionally, the metal is also coated in light oil which protects it from the moisture in the air.  Like most metals, galvanized is no exception to the threat of moisture, and can rust.  The rust will appear white, and will need to be removed by washing with water and a detergent, followed by a thorough rinsing.

Galvanized metal requires specific surface preparation.  The oil coating can prevent proper paint adhesion, and will cause peeling and paint failure.  Additionally, peeling may result if an alkyd or oil-based product is applied over a bare galvanized surface.  Galvanized metal uses zinc, and when the alkyd or oil-based paint reacts with the zinc, it creates a soap film, causing separation and application failure.

read more