🟨 When Coating Fails?
5 Causes and How to Avoid Them
Real-world examples and how to design better systems
A coating system is only as strong as its surface prep, product choice, and application method. Yet, coating failures are still common across industrial, commercial, and institutional sites — leading to costly repairs, downtime, and frustrated clients.
In this article, we break down the top 5 causes of coating failure, show how to recognize the warning signs, and explain how to prevent them through smart system design and proper product selection.
⚠️ 1. Poor Surface Preparation
The #1 cause of failure — and the most preventable.
If the surface is dirty, oily, sealed, or improperly profiled, even the best coating will fail. Lack of adhesion leads to:
- Peeling
- Blistering
- Delamination
How to avoid it:
• Always clean, degrease, and mechanically profile the substrate (grinding, shot-blasting, etc.)
• Test for moisture, pH, and contamination before applying primers or coatings
💧 2. Moisture in the Concrete Slab
Invisible moisture = visible failure.
If a coating is applied to a slab with too much internal humidity, water vapor pressure can cause:
- Blisters
- Bubbles
- Coating lift
How to avoid it:
• Always test moisture content with a calcium chloride or RH test
• Use a moisture vapor barrier (MVB) like:
MAGIECHEM 975 Polyaspartic MVB for up to 5%
MAGIECHEM 5076 Epoxy MVB for up to 5%
MAGIECHEM 5087 Epoxy MVB for 5%+ or 24-hour fresh concrete
🧪 3. Incompatible Coating Systems
Not all coatings play well together.
Layering the wrong topcoat over a base system — or mixing incompatible chemistries — can lead to:
- Cure inhibition
- Cracking
- Soft or uncured surfaces
How to avoid it:
• Always verify product compatibility between layers
• Use systems tested and designed to work together
• When recoating, ensure the substrate is properly sanded and compatible with the new chemistry
🌡️ 4. Improper Environmental Conditions
Temperature and humidity matter.
Applying a coating when it’s too hot, cold, humid, or windy can affect:
- Open time
- Cure speed
- Adhesion and finish
How to avoid it:
• Respect application windows in each product’s TDS
• Choose systems formulated for cold or humid conditions, such as MAGIECHEM polyaspartics that cure even at low temperatureshether you’re refreshing a worn surface, upgrading chemical resistance, or going for a decorative finish.
🎯 5. Incorrect Mixing or Application
Rushed or careless application ruins systems.
Wrong mix ratios, under-mixing, improper tools, or uneven thickness can result in:
- Soft spots
- Inconsistent cure
- Delamination or texture issues
How to avoid it:
• Use a clean drill with proper paddle
• Follow mixing instructions precisely
• Use wet film gauges to verify thickness
• Allow the product to induct if required
Always follow the MAGIECHEM Installation Guide provided with each system. If in doubt, ask our reps for clarification before starting.
🧠 Final Thoughts
Coating failures can cost you more than just materials — they damage your reputation.
By understanding these 5 key causes and working with the right systems, you can ensure long-lasting, high-performance results every time.
MAGIECHEM offers fully integrated, field-tested coating systems — supported by expert technical reps and precise product documentation.
