EPC Contract indicated “the project site is subjected to moist and heavily polluted salt laden air”…
While the contractor took precautions to properly specify the coating systems, the surface prep and coatings application was flawed anyway. Normally, an effective shop (or field) inspection program will catch the problem early and be resolved in favor an effective coating process. In this facility, there was extensive evidence that either no QC program existed, or the inspector(s) were compromised.
After 18 months in operation, the coatings appear 15 years old. To varying degrees, most of the structural steel coating systems in the subject plant are in a progressive state of failure with the substrates rapidly and increasingly unprotected.
It was determined much of the steel coatings suffer from varying failure mechanisms. However, this photo is an example of improper surface prep (NACE/SSPC) and inconsistent dry film thickness, often with a top-coat greatly exceeding manufacturers requirements.
Minimal to no cost savings. Some time may have been saved if rework in the shops had been required.
Owner: Coating system will need an aggressive repair program as opposed to the anticipated touch-ups. Magnitude large but unknown.