Failure Analyses
Understanding Coating Failures—And Solving Them
Coating failures can occur for many reasons, and the visible failure is often only a symptom of a larger underlying problem. Whether the issue is blistering, peeling, delamination, cracking, rusting, discoloration, premature weathering, or chemical attack, identifying the true root cause is critical to preventing repeat failures and unnecessary repair costs.
For more than 20 years, I have conducted coating failure investigations across a wide range of industries and environments, including water and wastewater facilities, pipelines, industrial facilities, commercial structures, manufacturing plants, and transportation infrastructure. I have also trained inspectors, contractors, and coating professionals in the systematic process of coating failure analysis.
A successful failure investigation goes beyond identifying what failed. The objective is to determine why it failed.
My investigations may include:
- Detailed visual inspection and documentation
- Review of project specifications and application records
- Evaluation of surface preparation methods and conditions
- Dry film thickness measurements
- Adhesion testing
- Assessment of environmental exposure conditions
- Identification of coating materials and coating systems
- Evaluation of substrate condition and corrosion activity
- Laboratory testing when required
- Analysis of contributing factors and root causes
Common coating failures investigated include:
- Adhesion failures
- Delamination and peeling
- Blistering and osmotic blistering
- Rusting and underfilm corrosion
- Cracking and checking
- Chalking and weathering
- Chemical attack and immersion-related failures
- Premature coating degradation
- Overcoating failures
- Application-related defects
My goal is to provide clear, unbiased findings and practical recommendations that help owners, contractors, engineers, manufacturers, and legal teams understand what happened, why it happened, and what steps should be taken moving forward.
With more than 40 years in the protective coatings industry and over two decades dedicated to coating failure investigations, I bring a combination of field experience, laboratory knowledge, and practical problem-solving to every project.
When a coating system fails, the most important question is not "Who is at fault?" but rather "What caused the failure, and how can it be prevented from happening again?"
