May 2023 Vol. 2

PCN – Communicating News In Protective Coatings Globally in Real-Time

Leading Source of Industry News on Protective Coatings for Oil & Gas, Pipelines, Marine and Construction

NEWSMAKERS:  * Acotec * Akzo Nobel * Arizona Pipeline Explosion * Baltoflake™ * Carboline * Cerium Oxide * Coating Condition Survey * Copsys * CUI * ExcelPlas Labs * Epoxy Phenolic Coatings * Failure Analysis * Graphene Oxide * Humidur™ * Hyperspectral Imaging * Jotun * INPEX * Intertherm 228 * PCN * Protective Coatings * Self-Healing Coatings * Smart Coatings * ZenArmour™ * Zentek


Read Latest Judgement in Akzo Lawsuit Involving Intertherm 228 [PDF]

Acotec’s Humidur® Coatings for LNG and Oil & Gas to be Manufactured Under License in Australia

Arizona Pipeline Explosion Linked to Incorrect Protective Coating


Zentek has Developed ZenARMOR™, a Novel Corrosion Protection Coating Based on Functionalised Graphene Oxide

New Method for Quantifying Early Corrosion of Coated Steel Assets Using Hyperspectral Imaging

Top 5 Essential Steps to Avoid Protective Coating Problems on Oil & Gas Assets (Special Feature) [PDF]

Corrosion Protection Practices and Integrity Management Challenges in Oil and Gas Pipelines

Rise in Offshore Wind Operations Calls for Tried and Tested Anti-Corrosion Coatings

Game Changer for Coatings Under Insulation
Corrosion under insulation (CUI) continues to be one of the key coating integrity challenges associated with insulated equipment. Copsys Intelligent Digital Skin detects and locates coating barrier damage or CUI hotspots in real time before corrosion damage can occur. The integrated impressed current cathodic protection within the coating creates an entirely new category of continuous sensor technology. Consisting of an epoxy resin with Copsys proprietary additives and proprietary polyamine hardener, Copsys Intelligent Digital Skin is the first technology to digitally detect and locate coating damage.

Essentials of Bridge Coatings for Protecting Our Infrastructure (Online Exclusive)


Effect of Graphene Incorporation on Properties of Epoxy-Based Self-Healing Coatings

Engineering Active-Site-Induced Homogeneous Growth of Polydopamine Nanocontainers on Loading-Enhanced Ultrathin Graphene for Smart Self-Healing Anticorrosion Coatings

Reliability Evaluation of a New Method Developed for DSC Curing Kinetic Model of Epoxy Coatings

Stable Anticorrosion Coating with Multifunctional Linkage Against Seawater Corrosion

Functionalization of Graphene Oxide with an Ionic Liquid for Preparation of Epoxy‐based Coatings on Carbon Steel for Anticorrosive Applications

Novel Cerium Organic Network Modified Graphene Oxide Multifunctional Epoxy-based coating with Excellent Mechanical and Passive/Active Anti-Corrosion Properties

Superhydrophobic Nanoparticles Incorporated Epoxy Coatings for Self-Cleaning and Anticorrosive Applications

Preparation of CeO 2-PPy Nanocomposites to Improve Corrosion Resistance of Epoxy Resin Coatings

Field Tests of Protective Epoxy Coatings in a Humid Tropical Climate

Mussel-inspired preparation of Superhydrophobic Mica Nanosheets for Long-Term Anticorrosion and Self-Healing Performance of Epoxy Coatings

Corrosion Resistance of Graphene/Basalt Flake Modified Epoxy Zinc-Rich Primer

Development of pH-Sensitive UiO-66/Polyaniline Nanohybrids with Self-Healing Anticorrosive Performance in Epoxy Coatings

Highly-Compact MXene-based Epoxy Coatings by Controllable Interfacial Structures

Characterisation of the Galvanic Protection of Zinc Flake Coatings by Spectroelectrochemistry and Industrial Testing

Exploring Epoxy Coating Failures with ExcelPlas
While epoxy coatings are generally durable and effective at preventing corrosion, there are a few common types of epoxy coating failures that can occur:

  • Adhesion failure: This occurs when the epoxy coating fails to properly adhere to the surface of the pipe, which can be caused by factors such as improper surface preparation or a poorly formulated coating. Adhesion failure can result in the coating peeling or flaking off, exposing the underlying steel surface to corrosion.
  • Blistering: This occurs when small bubbles or blisters form on the surface of the epoxy coating, which can be caused by improper surface preparation, moisture contamination, or excessive heat during curing.
  • Cracking: This occurs when the epoxy coating develops small cracks, which can be caused by factors such as thermal expansion and contraction, improper coating thickness, or exposure to chemicals.
  • Delamination: This occurs due to intercoat or interfacial adhesion failure due to the presence of a weak boundary layer such as silicone or hydrocarbon oil contamination.


Failure Analysis and Investigation of Protective Coatings in Mining, Marine Offshore Oil & Gas Chemical Plants, Energy Infrastructure and Bridges (Ask the Experts)

Critical Questions for Protective Coatings for Asset Protection in Oil & Gas, LNG:

  • Why is the coating not stopping corrosion?
  • Why is the coating delaminating or blistering?
  • Has the coating been correctly specified / applied?
  • Does the coating meet the manufacturing standard, including properties such as correct hardness/cure, adhesion and thickness?
  • What surface preparation and atmospheric conditions must be achieved to successfully apply the coating?
  • Does the coating have any defects in it? How will these affect performance?
  • Why did the coating fail? Root cause assessment.
  • How can the coating be successfully repaired/remediated so that it doesn’t fail again?

ExcelPlas Labs can answer these questions and more…


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This newsletter is brought to you by ExcelPlas Coating Labs (

ExcelPlas Labs provides independent testing, analysis, and investigation on protective coatings to prevent corrosion.

ExcelPlas has extensive analytical capabilities for testing of Protective Coatings and Insulation Consulting for major oil and gas companies.

We conduct corrosion surveys, coating sampling, coating analysis, and testing to ensure coating specifications for a wide range of onshore and offshore clients in Australia and the Asia-Pacific Region.

ExcelPlas Labs offer a full range of coating testing and analytical services to Australia’s mining, oil, gas, and infrastructure sectors.

Forensic analysis for undertaking various coating-based failure investigations and problem-solving.

ExcelPlas Undertakes Analysis & Testing of Polymer Coating Systems including:

  • Epoxy Protective Coatings
  • Epoxy-Phenolic Protective Coatings
  • Fusion bonded epoxy (FBE) 
  • Dual-Layer Fusion bonded epoxy (DLFBE)
  • Liquid applied epoxy (LAE)
  • Abrasion-resistant overcoat (ARO)
  • Three-layer PE (3LPE)
  • Multi-component liquid spray  (MCL)
  • Heat shrink sleeves (HSS)

Testing on Coatings that ExcelPlas can Undertake includes:

  • Coating identification by Infra-red Analysis (FTIR)
  • Degree of Cure by Thermal Analysis (DSC)
  • Coating Filler Identification by X-ray Analysis (EDS/XRD)
  • Coating Microstructure by Embedding, Polishing, and Optical Microscopy (OM)
  • Coating Thermal Stability and Composition by Thermogravimetric Analysis (TGA)

DSC – Phase transition/volatiles / Tg / degree of cure/characterisation
TGA – Volatile compounds, inorganic mass % mix ratio
Element mapping for chlorides on paint flakes
Microscopy -Count layers and thickness of layers

  • Assess porosity and voids
  • Check distribution and orientation of filler particles

Condition monitoring and analysis of corrosion prevention coatings (epoxies, epoxy-phenolics)

Testing of Epoxy Coatings (LAE, FJC, FBE), heat shrink sleeves and tapes, barrier tapes, and meshes.

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