October 2021 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:  * Akzo Nobel * BASF * Carboline * Chugoku Marine Paints * EUROPORT 2021 * ExcelPlas * Graphene Oxide-Modified Epoxy (GOME) * Jotun * International Paints * LNG Plants * Marine Coatings * PCN * PPG * Protective Coatings * RPM Coatings * Sherwin Williams * Silicone Acrylic (SA) Coatings


Coating Chemist Convicted of Stealing US$120Mil Worth of Trade Secrets on Epoxy Coatings from Akzo-Nobel, BASF, PPG, and Sherwin Williams

News Release from Chugoku Marine Paints, Ltd. – Reducing CO2 Emissions by Providing Premium Performance Antifouling Coatings

Chugoku Marine Paints to Exhibit Their Latest Anti-Fouling Coatings at Europort 2021 (2nd-5th November, 2021)

Growth Plan to Push Hempel into the Global Top Ten of Paint Producers

Major Anti-Fouling Paint Maker Travels the Robot Hull Scrubber Route

Marine Coatings Market: Floating Towards Slight Growth

AkzoNobel’s Hull Management System Sets New Standards for Marine Industry

RPM Releases 2022 Q1 Earnings Report – Sales Increased to a Record $1.65 Billion

Carboline LNG Case Study – Silicon Acrylic (SA) Protective Coating is Applied on Scalding Exterior Surface of Regasification Stacks at Major LNG Plant


Investigation of the Anti-Corrosion Properties of Galactomannan as Additive in Epoxy Coatings for Carbon Steel: Rheological and Electrochemical Study

Epoxy-Ester Coating Reinforced with Cerium (III)-Tannic acid-based Hybrid Pigment for Effective Mild-Steel Substrate Corrosion Protection

Recent Advances of Metal-Organic Frameworks (MOF) for Epoxy Coatings in Corrosion Protection: from Synthesis to Applications

Multifunctional Epoxy Nanocomposite Coatings Reinforced by Two-Dimensional Materials: A Review

Reinforced Anticorrosion Performance of Epoxy Coating with Eco-friendly L-Cysteine Modified Ti3C2Tx MXene Nanosheets

Chemical Modification of Epoxy Prepolymers as Anticorrosive Materials: A Review

Low Loading of Tannic Acid-Functionalized WS2 Nanosheets for Robust Epoxy Nanocomposite Protective Coatings


15 of the Most Common Causes of Failure of Protective Coatings & the Type of Failure (from ExcelPlas’ 25 Years of Experience)

  1. Inadequate blasting and insufficient removal of mill scale from the steel leading to poor adhesion
  2. Use of blasting grit with soluble salt contamination leading to osmotic blistering and under film corrosion
  3. Oil contaminated compressed air used for blasting leading to surface contamination leading to poor adhesion and delamination of the coating
  4. Inadequate blast profile i.e. shallow valleys leading to poor adhesion
  5. Excessive blast profile i.e. high peaks leading to poor steel coverage and risk of rust-rash corrosion, particularly for low DFT coatings.
  6. Excessive delay between blasting and coating causing flash corrosion contamination leading to poor adhesion and corrosion cells
  7. Addition of too much thinner that increases the potential for porosity and pinholes in the coating. There is also an increased propensity for the formation of Bernard Cells where there are boundaries of resin rich coating, resulting in “crow’s feet” cracking.
  8. Poor mix ratio of the epoxy with the hardener leading to incomplete cure
  9. Inadequate mixing/stirring of the coating before application leading to poor distribution of barrier pigments leading to coating cracks and premature corrosion
  10. Inadequate coating specification: lack of suitable topcoat for UV sensitive epoxies leading to chalking and UV breakdown
  11. Inadequate curing of coatings leading to less than optimal properties of the coating with increased moisture penetration and formation of corrosion cells
  12. Incompatibility of coating if different paint systems are used multicoat application leading to delamination/peeling
  13. Poor QA leading to inadequate control of coating thickness (e.g. excessive DFT) leading to cracking of the coating due to residual stresses
  14. Poor QA leading to inadequate control of coating thickness: low coating thickness or missing coats can lead to poor barrier performance and premature corrosion
  15. Exceeding the recoat window leading to delamination of topcoat from primer coat due to blast-dust contamination or lack of interfacial adhesion.


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


PCN – Communicate Your Message Instantly With the Entire Global Protective Coatings Community

This newsletter is brought to you by ExcelPlas Coating Labs (http://www.excelplas.com/)

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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