Comprehensive Guide to Coating Defects
1. Pinholes
Tiny pits or pores in the film.
Cause: Air, solvent, or moisture trapped escapes during cure.
Fix: Proper surface clean; adjust spray technique; apply mist coat on porous substrates.
2. Blistering
Dome-like raised bubbles on the surface.
Cause: Moisture or solvent vapor pressure builds under film.
Fix: Ensure dry substrate; use moisture-tolerant primers; remove blisters, prep surface, recoat.
3. Cracking / Alligatoring
Network of cracks-either fine (crazing) or coarse (alligatoring).
Cause: Heavy film, inflexible systems, fast cure or incompatible layers.
Fix: Control film thickness; allow full cure between layers; use compatible, flexible coatings.
4. Delamination / Peeling
Entire coating or layers lift away from substrate.
Cause: Poor prep, contamination, or missed recoat window.
Fix: Achieve proper blast or etch prep; clean surface; remove failed coating and reapply correctly.
5. Sagging / Runs
Thick drips or trails running downward.
Cause: Excessive wet film or low viscosity, especially on vertical surfaces.
Fix: Spray thinner coats, adjust viscosity and equipment; sand and recoat if needed.
6. Fish Eyes / Cratering
Circular depressions surrounded by raised edges.
Cause: Silicone, oil, or grease contamination.
Fix: Thorough cleaning and degreasing; optionally add fish-eye eliminator; recoat.
7. Orange Peel
Rough, dimpled finish resembling citrus peel.
Cause: Poor atomization, improper thinning, wrong gun settings.
Fix: Optimize viscosity, spray technique, pressure, distance; sand smooth and reapply.
8. Chalking
Powdery residue on surface from binder breakdown.
Cause: UV/weather exposure degrading binder.
Fix: Clean to remove powder; apply UV-resistant topcoat.
Comprehensive Guide to Coating Defects
9. Cissing
Blotches or pinholes due to poor wetting.
Cause: Surface contamination or moisture.
Fix: Clean surface; ensure correct flash-off; treat with adhesion promoters if needed.
10. Mud Cracking
Deep, web-like cracks in thick coatings.
Cause: Excessive film, stress, or rigid systems.
Fix: Strip and prepare surface; apply thinner coats; use flexible or proper systems.
11. Bleeding / Staining
Underlying contaminants or dyes bleeding through.
Cause: Solvent action dissolving substrate materials.
Fix: Strip and prep; apply tie-coat or blocker; recoat with compatible layers.
12. Blushing / Bloom
Dull, hazy film due to moisture.
Cause: High humidity, cold temps, or fast solvent evaporation.
Fix: Control temperature/humidity, slow solvent, or use retarder; sand and recoat.
13. Fading / Discoloration
Uneven or faded color areas.
Cause: UV exposure, poor pigment stability, or chemical attack.
Fix: Use UV-stable pigments; mix correctly; apply UV-resistant clearcoats.
14. Rusting / Corrosion Spots
Red/brown rust blemishes under film.
Cause: Poor prep or excessive moisture on steel.
Fix: Remove rust, profile substrate; use corrosion-resistant primer and proper system.
Summary Table: Root Causes and Related Defects
Root Cause Defects
Poor Surface Prep Peeling, blistering, cissing, rusting
Contamination Fish eyes, staining, cissing
Improper Application Sagging, orange peel, runs
Incorrect Film Thickness Cracking, mud cracking, sagging
Environmental Issues Blushing, blistering, chalking
Incompatible Systems Alligatoring, cracking, staining