ApplicatorTrainingBulletin
Recognising and Correcting
Paint Application Deficiencies
T he job of a coatings applicator is
to apply paint in an even, uniform
film according to the specification. Any
defects in the paint job caused by the
application must be corrected or else the ✔ Ltd., Gateshead, UK.
work will not be accepted. Nobody is
perfect; even the most skilled painter can make a mistake
now and then. So, this month’s Applicator Training Bulletin
reviews common types of application defects, their causes,
how to prevent them, and methods of correction.
Runs and Sags
Runs and sags are downward movements or “tears” of
paint that appear soon after application to vertical sur-
faces. In severe cases, the defect is described as curtaining.
Causes include excessive application of paint, excessive
use of thinners, or just poor workmanship. In extreme cir-
cumstances, the cause could be a formulation problem,
such as lack of a curing agent or use of the wrong curing
agent in the coating material. To avoid runs or sags, cor-
rect application techniques and suitably formulated prod-
ucts should be used. To correct this type of defect while
the paint is still wet, the runs or sags can be brushed out.
When the paint has dried, defective areas can be abraded
and cleaned, and then an overall coat can be applied or
spot repair work can be done as needed.
Dry Spray
Dry spray is a rough, powdery, non-coherent paint film that
occurs when atomised paint particles partially dry before
reaching the intended surface. The paint particles are insuf-
ficiently fluid to flow together, and they are often poorly ad-
hered. This may be the result of incorrect spray application
Runs and Sags Dry Spray
56 PCE May 2000
This month’s column, originally published in the
January 1992 issue of JPCL, was reviewed and
revised for PCE by Brendan Fitzsimons of Pyeroy
(i.e., the spray gun is too far from the surface), fast-drying
products, or too high an application temperature. Dry spray
can be avoided by using the correct application equipment
and techniques; by using a slower drying solvent or solvent
blend; and by following recommended application proce-
dures. It can be repaired by abrading and removing any
loose dry spray and then reapplying the coating.
Orange Peel
Orange peel, a uniformly pock-marked paint film that re-
sembles the skin of an orange, results from the failure of
spray-applied coating material to flow out. It is usually
caused by poor application techniques or by incorrect sol-
vent blend. This defect can be avoided by proper applica-
tion techniques and use of suitably formulated products.
Where aesthetics are a concern, orange peel can be re-
paired by abrading the overall surface and then cleaning
and recoating it.
Mud Cracking
In this defect, the paint film looks like a dried-out mud
bath. Cracks vary in size and amount but form a network.
Mud cracking is generally caused by excessive application
of heavily pigmented coatings. This defect can be avoided
by applying the recommended coating thickness of suit-
ably formulated products and by using recommended ap-
plication techniques. For repairs, all cracked and flaking
Orange Peel Mud Cracking
Copyright ©2000, Technology Publishing Company
 ApplicatorTrainingBulletin
Wrinkling Pinholes
paint is removed to a sound base; the surface is then abrad-
ed and cleaned; and the coating is reapplied to the manu-
facturer’s recommendations.
Wrinkling
Development of wrinkles in a paint film during drying is
usually due to the initial formation of a surface skin on sol-
vent-borne paints or swelling of the coating from solvent
attack. It also can result from overcoating before the previ-
ous coat has adequately hardened. To avoid wrinkling, an
applicator should follow the coating specification, ensure
adequate mixing of the coating material, use correct appli-
cation techniques, and allow adequate time for curing. The
paint supplier’s recommended overcoating times should be
followed. To repair wrinkling, remove the defective coat-
ing, abrade, clean, and recoat.
Pinholes
Pinholes form in a wet paint film during application and
drying as air or gas bubbles burst and create tiny holes that
fail to coalesce before the film dries. This defect is caused
by entrapment of solvent or air within the film. Pinholing
is a common problem when coating porous substrates such
as zinc-filled primers, zinc silicates, and metal-sprayed
coatings. It also can be caused by incorrect spray applica-
tion or use of incorrect solvent blends. This defect can be
avoided by use of correct application techniques (i.e.,
maintaining a proper distance between the spray gun and
the surface), suitably formulated products, and correct sol-
vent blends. To repair pinholes, abrade and clean the sur-
face and apply a suitable tie coat/undercoat and topcoat as
needed.
Delamination
Delamination is the loss of adhesion between coats of paint
or between paint and the surface. If compatible paint ma-
terials are used, delamination defects are generally related
PCE May 2000
Copyright ©2000, Technology Publishing Company
Delamination Fish Eyes
Photos courtesy of Brendan Fitzsimons, Fitz’s Atlas of Coating Defects
to poor surface preparation or application defects (e.g.,
contamination of the surface between coats, overcoat times
being exceeded, or application to a glossy surface). To
avoid these problems, ensure there is no surface contami-
nation between application of subsequent coats; closely
follow the manufacturer’s suggested overcoat times; and
lightly abrade and clean glossy surfaces between coats. De-
pending on extent of the delamination, the surface can be
abraded and recoated, or the coating can be completely re-
moved and a new coating applied.
Fish Eyes
Fish eyes are surface breaks—sometimes very large—in a
wet paint film where the paint recedes to expose the un-
derlying substrate. This defect, also known as cissing or
crawling, occurs when the paint is unable to wet out the
substrate because of contamination by moisture or foreign
matter such as oil, grease, silicone, etc. It also can result
from the use of incorrect solvent blends in the paint. To
avoid this problem, the surface should be clean and free
from contamination prior to coating application. To reme-
dy the defect, the coating must be completely removed and
the surface must be thoroughly cleaned before application
of a new coating according to the manufacturer’s recom-
mendations.
Conclusion
A professional painter should be aware of these common
defects and know how to avoid and repair them. Many of
them are easily corrected while work is being performed.
Minimising or avoiding them comes with experience and
practice.
Next month: Detection and Removal of
Invisible Contaminants
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