Understanding Coatings Failure Analysis

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NEWSMAKERS:  * Avantguard™ * Akzo Nobel * AMPP * ANIP * Carboline * Coating Condition Survey * Coating Failures * Chugoku * CMP * CUI * Epoxy Coatings * Epoxy Phenolics * ExcelPlas Labs * Failure Analysis * Graphene * Hempadur™ * Hempafire™ * Hempel * Humidur™ * Intergard™ * International Paints * Jotun * Matrix Engineering * MIC * PPG * Protective Coatings * Sustainable Coatings * Thierry Vanlancker

INDUSTRY NEWS

Main Guidance Document Published for Acceptable Paint Coatings for All In-Service and New-Build Royal Naval (RN) Vessels OFFICIAL – CLASSIFIED [PDF]
Chugoku Camideck™, Hempel Hempadur™, International INTERGARD™, Jotun Hardtop™, PPG Sigmadur™ 540, Sherwin-Williams Epidek™ & Macropoxy™

Failure Analysis of Protective Coatings: Insights for Materials Engineers

The Crucial Role of Corrosion Protection in Steel
Coatings specialist Hempel has introduced its latest innovation in steel protection, Avantguard™ 750 Pro, with the aim of addressing critical environmental and economic challenges through improving steel durability. 

Matrix Successfully Demonstrates New Humidur® FP Application Method Using a Single Leg Pump—Expanding Capabilities and Flexibility

An Interview with Thierry Vanlancker, former CEO of AkzoNobel

Hempel Launches Hempafire™ Extreme 550 for Passive Fire Protection
Hempel has launched Hempafire Extreme 550, a market-leading epoxy Passive Fire Protection (PFP) coating certified for up to four hours of fire resistance

Corrosion: The Hidden Threat in America’s Shipbuilding Revival
By D. Terry Greenfield, Principal Consultant, CONSULEX

Epoxy Coatings with Memory: Light-induced Colour Change and Self-Healing Thanks to Azobenzene
A research team has developed an intelligent epoxy coating that reacts to UV light: it reversibly changes colour, displays temporary images and heals itself. This is made possible by azobenzene and fluorinated polyurethane precursors.

Corrosion Protection Coatings in Industry: Methods and Innovations

Multifunctional Anti-Corrosion Coatings Based on 2D/3D Structure-Function Integrated Nanomaterials for Steel Protection

Microbiologically Influenced Corrosion (MIC) in Uncoated and Coated Mild Steel

NEW RESEARCH THAT IS TRENDING

Liquid-Repellent and Self-Healing Epoxy Resin Coating with High Mechanical Stability
Chinese researchers have developed a novel, liquid-like epoxy resin coating with outstanding non-stick, self-healing and recycling properties. This is made possible by the use of dynamic disulphide bonds in combination with hyperbranched epoxy resin and silicone components.

Hydrolysis Degradation Mechanisms of Epoxy Resin Coatings in Hydrothermal Environment Resolved by Molecular Dynamic Simulations

Synthesis of Robust Superhydrophobic EP/F-CNTs/SiO2 Composite Coatings with Excellent Anti-Corrosion and Wear-resistant Properties

Low MXene Loading of Epoxy Coating with Enhanced Hydrothermal Resistance

Smart Epoxy Nanocomposite Containing Zr-Mof Loaded with a New Schiff Base for Corrosion Protection of Steel

Incorporating Graphene-Modified Mica and Conductive Nickel Particles for Enhanced Corrosion Resistance in epoxy Zinc-Rich Coatings

Enhanced Antibiofouling and Corrosion Resistance of CeO2-Functionalized Polydopamine-Modified Two-Dimensional Zeolitic Imidazole Framework-7 (2D ZIF-7) Nanosheets

Two-dimensional Nanocontainers Enhance Long-term Corrosion Protection of Water-Borne Epoxy Coatings

Smart Corrosion Protection: New Epoxy Coating with Self-healing Carbon Nanotube-Based Nanocarriers
Zinc- and sodium gluconate-modified carbon nanotubes enhance the barrier performance and provide effective self-healing properties for a new epoxy coating.

Smart Epoxy Nanocomposite Containing Zr-Mof Loaded with a New Schiff Base for Corrosion Protection of Steel

Exploring a Feasible Inhibitor-Coating Protective System for Corrosion Protection of Steel

Impact of Polyaniline-Gum Rosin Composite Loaded with Alumina for Improving Corrosion Prevention Performance of Epoxy Coating

Bio-based Polyurethanes: Enhanced corrosion protection and luminescence through fluorescent azine segments

Two-Dimensional Nanocontainers Enhance Long-term Corrosion Protection of Water-Borne Epoxy Coatings

IN CASE YOU MISSED IT !

Hempel Boss Calls Russian Market a “Totally Closed Door”
The coating maker halted its Russian activities in 2022 – a decision that will remain in force, says chief exec Michael Hansen.

Coating Major Jotun Pursues Robotics for Hull Cleaning
Jotun’s coatings helped shipping save both fuel and 11.1 million tons of CO2 emissions in 2024. The company now enbarks into robotics to hull cleaning.

Container Ship Sector Seeks to Improve Ship Coating Performance Monitoring
Conference highlights advances in performance monitoring, and the potential for further improvements 

International® Releases Whitepaper on Data-Driven Hull Performance Management
AkzoNobel’s marine coatings brand, International®, released a whitepaper examining how collaboration between coating experts and vessel operators can support performance consistency and emissions compliance through data-driven hull management.
The paper includes a case study tracking three LNG vessels coated with Intersleek 1100SR over a 60-month period. Underwater inspections showed minimal biofouling, and the vessels maintained energy efficiency targets in line with Carbon Intensity Indicator (CII) expectations.

Chugoku (CMP) Announces Strategic Expansion in Europe
In January 2025, CMP announced the acquisition of Italian coating manufacturer Italo Belge Colori S.r.l. (ITB) through its European subsidiary, CHUGOKU PAINTS B.V. This move aims to enhance CMP’s production capacity and reduce delivery times in Europe, supporting its growth strategy in the region. 

Chugoku Marine Paints (CMP) Transfer of Tokyo Headquarters to New Office Building
Chugoku Marine Paints, Ltd. is pleased to announce that our Tokyo Headquarters will be relocating to a new office building as follows, in order to consolidate our offices, which are currently spread over two floors, onto a single floor, and to improve internal communication and increase operational efficiency.

Akzo Nobel CEO Gregoire Poux-Guillaume Says Akzo Nobel Maintains FY Forecast in Wake of Tariff Impacts

Akzo Nobel Q1 Results Down; Confirms FY25, Mid-term Outlook

Carboline Names Dr. Ali Shah VP of Global Research, Development, and Innovation for Coatings

COATINGS FAILURE ANALYSIS

Exploring Epoxy Coating Failures with ExcelPlas Labs
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.

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

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 (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)
http://www.excelplas.com/

Testing of Epoxy Coatings (LAE, FJC, FBE), heat shrink sleeves and tapes, barrier tapes, and meshes.
http://www.excelplas.com/

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