Premature failure of anti-corrosion coating on steel structures

Thread Content

This diagram shows the outdoor steel structure of the production units at a petrochemical refinery; it is a newly built facility, and the element in question are the supports for the platform stairs (round tubes). Rust removal by manual or mechanical means shall be achieved to St3 level as required, with the primer and topcoat thickness exceeding 150 microns. Inspection of the damaged coating revealed no primer, with the topcoat thickness being around 100 microns. The anti-corrosion material is an acrylic-based material. Reason for failure: First, the surface treatment did not meet the requirements ； Second, it is the primer layer; the topcoat is too thin and does not meet the requirements. Due to the thin coating, there is a high porosity, a lack of primer, and inadequate surface preparation; the combined effect of these issues leads to premature failure of the anti-corrosion coating. The reason for the failure was mainly the negligence of our project supervisors in quality inspection, which led to the construction workers not following the construction plan in this regard. Although the construction company is at fault when negotiating with the owner, it is still the owner who suffers the losses. Regarding quality control in this area, our supervisors first examine every step of the construction process thoroughly. Whether it is the surface treatment or each coat of paint, the entire process must be inspected to ensure that the material achieves a high quality of construction. This image serves as a reminder to the entity using the service or the construction party to pay attention to construction and its management.