Paint Defects

Manual
Table of Contents
Adhesion Loss, Clearcoat pg. 3

Adhesion Loss, Plastic Parts pg. 4

Adhesion Loss, Polyester pg. 5

Bleeding pg. 6

Blistering pg. 7

Chipping pg. 8

Clearcoat Yellowing pg. 9

Color Mismatch pg. 10

Corrosion pg. 11

Cracking pg. 12

Dirt Inclusion pg. 13

Dissolution pg. 14

Dry Spray pg. 15

Edge Mapping, Shrinkage pg. 16

Edge Mapping, Solvent Penetration pg. 17

Environmental Contamination pg. 18

Fish Eyes pg. 19

Hiding pg. 20

Lifting pg. 21

Matting pg. 22

Mottling pg. 23

Orange Peel pg. 24

Peeling pg. 25

Pinholling pg. 26

Polishing Marks pg. 27

Runs pg. 28

Slow Drying pg. 29

Solvent Pop pg. 30

Water Spotting pg. 31

Paint Defects Manual

Clearcoat Adhesion Loss

Adhesion Loss,
Clearcoat Description
Loss of adhesion between the
basecoat and the clearcoat.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Excessive film thickness of basecoat » Allow proper flash-off time of coats of » Sand, isolate if necessary, and refinish
basecoat and before applying clearcoat
» Intermediate and final flash-off
times of the basecoat too short » Apply proper film thicknesses of all
layers
» Wrong mixing ratio for clearcoat and
activator » Mix clearcoat correctly

» Follow system recommendations per

Technical Data Sheet(s)

3
Paint Defects Manual

Adhesion Loss,
Plastic Parts Description
Loss of adhesion of the refinish system and a plastic
part substrate. This defect is often noticed some
time after the painting took place.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Improper cleaning, drying (tempering) » Identify the type of plastic substrate » Remove all finish layers from the
or preparation - failure to remove and follow recommended paint system substrate
mold-release agents for that specific type of substrate
» Refinish using recommended paint
» Improper treatment » Thoroughly clean substrate to be system and preparation for type of
painted using recommended system plastic substrate to be painted
» Wrong identification of substrate
» Use recommended sealer/primer using
» Failure to use proper sealer/primer the correct mixing ratio of recommended
activator, flexible additive and thinner
» Failure to use proper/recommended
topcoat system » Apply sealer/primer to recommended
film build using recommended viscosity
» Clean and degrease the plastic part
properly. » Use topcoat as recommended for type
of plastic substrate to be painted

» Where recommended, use a suitable

adhesion primer for the type of plastic
substrate being finished

4
Paint Defects Manual

Adhesion Loss,
Polyesters Description
Loss of adhesion between the
polyester filler and the substrate.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Substrate not carefully prepared » Clean and sand substrate thoroughly » Sand the damaged repair area well

» Polyester material unsuitable for » Follow the manufacturer’s instructions » Redo the repair and refinish
galvanized substrate for forced drying

» Too high surface temperature during » Use proper mixing ratio of polyester
forced drying materials

» Undercured filler - too much or too » Ensure the hardener is thoroughly

little hardener mixed

5
Paint Defects Manual

Bleeding
Also known as: bleed through, staining, stains
Description
Original finish color or peroxide hardener from polyester
body filler seeping through the topcoat, causing a
discoloration of the new finish.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Reaction of pigments from the » Test old finish applying a coat of the » Remove polyester and re-do repair
original finish with solvents of the color on a small area if bleeding is
coat which has been applied on top likely to occur, if so apply sealer » Sand, isolate the original finish with
of it sealer and reapply the topcoat
» Use only the recommended quantity
» Contamination - usually in the form of of hardener when mixing the polyester
soluble dyes or pigments on the older putty or filler
finish before it was repainted (this is
especially true with older shades of » Check quantity of hardener, mix by
red) weight or use a dispensing machine

» Old finish not well sealed » Mix all putties or fillers thoroughly

» Use of too much hardener in the

polyester putty or filler

» Insufficient mixing of the polyester

putty or filler

6
Paint Defects Manual

Blistering
Also known as: moisture blisters, bubbling, blowing, bubbles
Description
Bubbles or pimples appearing in the
topcoat film, application.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Residue of sanding water in corners, » Always remove exterior trim » If damage is extensive and severe,
edges, crevices, or below decorative paint must be removed down to
strips » Clean substrate carefully. Blow and dry undercoat or metal, then refinish.
carefully
» Ambient humidity too high
» Thoroughly clean areas to be painted
» Improper surface cleaning or preparation before sanding. Be sure surface is
wrong thinner or reducer- moisture or completely dry before applying
air can be trapped in the film undercoats or topcoats.

» Excessive film thickness. insufficient » Don’t touch a cleaned area as the oils in
drying time between coats or too your hands will contaminate the surface
heavy application of the undercoats
may trap solvents which escape later » Select the thinner or reducer most
and blister the color coat. suitable for shop conditions

» Contamination of compressed air lines. » Allow proper drying time for undercoats
oil, water or dirt in lines and topcoats. Ensure each coat flash
before applying the next.
» When wet sanding polyester and
applying topcoat without enough time » Drain and clean air pressure regulator
for the water to evaporate. and compressor tank daily to remove
trapped moisture and dirt
» Incompatibility of materials

7
Paint Defects Manual

Chipping
Description
Small chips of a finish losing adhesion from the substrate, usually
caused by impact of stones or hard objects against the vehicle’s
finish. While the refinisher has no control over local road conditions,
he can take steps to minimize their effect the condition is known
beforehand.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Stones and other hard objects hitting » In recommending an appropriate » Repair area affected by chipping with
vehicle finish under high speed system, ask customer if the car is a flexible system. Areas to pay
frequently exposed to potential special attention to: front of hood,
chipping hazards. leading edge of roof, lower side
areas (rocker panels) and around
» Use a flexibilized primer surfacer wheel openings.
within the refinishing system

» Activated basecoat improves chip

resistance

8
Paint Defects Manual

Clearcoat
Yellowing Description
Discoloration causing the appearance of a
color mismatch to the adjacent panel after
the clearcoat is applied.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Wrong or contaminated hardener/ » Ensure lids are tightly replaced after » Allow the finish to properly dry, then
activator using activators or hardeners sand and refinish

» Incorrect clearcoat film thickness » Follow recommendations per Technical

Data Sheets

» Use recommended system activators

9
Paint Defects Manual

Color
Mismatch
Also known as: off shade, mismatch fading, off color
Description
The color of the repaired part differs from
that originally on the object being painted.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» The appropriate formula or alternate » Check color for variations and use the » Sand and refinish after having chosen
was not used right formula the right formula, tinted the existing
formula and/or set up the repair for a
» Incorrect spray gun setup or psi » Stir colors thoroughly blend.

» The original finish has changed due to » Polish adjacent panels to check the
weathering or exposure color

» Incorrect application technique » If necessary, follow the instructions of

(especially applicable to metallics), too our color guide to match the old finish
wet, too dry, poor hiding or coverage color

» The color was not well stirred » Use the spraying technique which
better adapts to the required color
» Variations of the OEM finish matching

» Spray a test panel for color verification

» Blend the color into adjacent panel(s)

10
Paint Defects Manual

Corrosion
Description
Surface of metal substrate is visible and shows
corrosion spots. Brownish-red for steel, white rust in
the case of aluminum substrates.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» The surface of the metal was » Treat metals with correct metal » Paint has to be stripped/sanded
contaminated (fingermarks, water) treatment and wash-primers back to the bare metal
before application
» Repair all chips and scratches before » Use the metal conditioner and a
» Paint removed by chipping, scratches, rust develops phosphoric acid wash primer
etc. (etchprimer) applicable for the
» Clean the vehicle thoroughly before substrate
» Inadequate pre-treatment of the applying refinish system
metal surfaces » Refinish
» Residue of water from sanding still
» Rust was not completely removed on the surface should be wiped off
before refinishing and allowed to completely dry before
applying refinish system.
» Destruction of paint film by
contamination

11
Paint Defects Manual

Cracking
Description
A series of deep cracks resembling mud cracks in a dry
pond. Often in the form of three-legged stars and in no
definite pattern, they are usually in the color coat and
sometimes the undercoat as well.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Excessive film thickness. Excessively » Don’t pile on topcoats. Allow sufficient » The affected areas must be sanded
thick topcoats magnify normal stresses flash and drying time between coats to a smooth finish, or in extreme
and strains which can result in cracking cases removed down to the bare
even under normal conditions. » Do not dry by fanning with compressed metal, and a full refinish system
air from the spray gun reapplied
» Materials not uniformly mixed
» Stir all pigmented undercoats and
» Insufficient flash times between coats topcoats thoroughly

» Incorrect use of additives » Carefully read and follow

recommendations in the Technical Data
» Substrate is too hot or cold Sheet(s). Additives not specifically
designed for a color coat may weaken
» Use of coats incompatible the final paint film and make it more
sensitive to cracking.
» Omitting the activator when mixing a
2K product

12
Paint Defects Manual

Dirt Inclusions Description

Also known as: bits, dirt in paint, seed, grains, specks, spikes, grits
A surface with this defect will show particles of
different sizes deposited in the primer or color.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Various types of contamination » Use anti-static fluid or attach the » Allow the finish to harden completely,
typically introduced during the drying vehicle to electrical earth fine sand and polish
process or application
» Keep bodyshop as clean as possible, » If the defect is severe, sand and
» Static charge on surface of vehicle. This keep spray booth doors closed. Wet respray.
condition helps the attraction of dust. floor and wall if necessary

» Debris from dry sanding, cloths, etc. » Wear special spraysuits

» Use of poor quality masking paper » Blow out all mouldings, seams etc
.
» Tack rag was not used before spraying, » Blow the vehicle out before placing it
or not immediately before in the spraybooth

» Inadequate filtration of air » Use the tack rag immediately before

applying each coat
» Dry spray dust settling on wet paint
» Care of the maintenance of the
» Dirty paint containers/tins equipment

» Paint was not strained » Follow the recommendations

(pressure, thinner) to avoid overspray
» Operators clothing bearing debris
» Clean the vehicle before starting the
» Expired paint repair

» Inadequate filtration of compressed air » Mix the color thoroughly after

sufficient stirring of tintings
» Incorrect activator or thinner
» Do not exceed the recommended
» The car was not thoroughly blown out potlife of 2K materials

» Tintings/pigments were not sufficiently » Use a fine strainer

stirred

» Spray dust accumulated in spray booth

» Use, re-thinned, of 2K materials after

the recommended potlife 13
Paint Defects Manual

Dissolution
Description
Metallic particles from the basecoat surface in the
clearcoat. If severe, the effect can alter the tone and
exagerate the metallic appearance.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Tack cloth was not used before applying » Use tack cloth, if possible » Sanding and refinishing are necessary
the clearcoat if the defect is severe.
» Use recommended products only, with
» Basecoat and clearcoat are incompatible recommended air pressure

» Clearcoat was applied with insufficient » Allow proper flash-off time of the
flash-off of the basecoat, or was applied basecoat before applying the clear
too wet
» Use recommended thinner/reducer
» Air pressure was too high
» Follow product recommendations in the
» Wrong thinner Technical Data Sheets.

» A coat of basecoat was too dry when

the next was applied

14
Paint Defects Manual

Dry
Spray Description
Granular texture normally with no gloss at all.
This defect is normally limited to small areas.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Incorrect viscosity » Follow recommendations on the » Allow the paint to dry and then sand.
Technical Data Sheet for mixing ratio After sanding, and depending on the
» Improper choice of thinner, reducer or and reduction, appropriate to spray magnitude of the defect, respraying or
activator; generally, too fast for spray conditions polishing will be necessary
conditions
» Adjust spray gun settings, fluid feed,
» Spraying too fast spray pattern

» Air pressure too high » Use recommended air pressure

» Spray gun too far from surface while

applying

» Improper spray gun setup

15
Paint Defects Manual

Edge Mapping,
Shrinkage
Also known as: featheredge splitting
Description:
Enlarged sand scratches caused by shrinking action of primer
layers that held excess solvent into the basecoat or topcoat
application, appearing at the area of the repair where it was
sanded through to the substrate.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» “Piling on” the undercoat in heavy » Apply properly reduced primer-surfacer » Thoroughly dry affected area
and wet coats. Solvent is trapped in in thin to medium coats following
undercoat layers which have not had recommended flash-off time between » Sand, isolate if necessary, and refinish
sufficient time to set up coats

» Material not uniformly mixed. Because » Stir all pigmented undercoats and
of the high pigment content of primer- topcoats thoroughly
surfacers, it is possible for settling to
occur after it has been thinned » Select only thinners/reducers that
are recommended for existing shop
» Improper thinner/reducer selection conditions

» Improper surface cleaning. When not » Thoroughly clean areas to be painted

properly cleaned, primer surfacer coats before sanding
may crawl or draw away from the edge
because of poor wetting and adhesion » Use proper sandpaper grit before
applying polyesters or undercoats
» Improper drying. Fanning with a spray
gun after the primersurfacer is applied » Follow product recommendations per
will result in drying the surface before its Technical Data Sheet
solvent or air from the lower layers is
released

» Finishing grit of sandpaper too coarse

16
Paint Defects Manual

Edge Mapping,
Solvent Penetration
Also known as: Sandscratch swelling, tramlining, lining up, flattingmarks,
Description:
Enlarged sandscratches caused by swelling action of
topcoat solvents, appearing at the area of the repair
sanding marks, scratch swelling
where it was sanded through to the substrate.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Improper surface cleaning or » Use appropriate grits of sanding » Thoroughly dry affected area
preparation. Use of too coarse material for the topcoats you are using
sandpaper or omitting a sealer in panel » Sand smooth, isolate with appropriate
repairs greatly exaggerates swelling » Avoid sanding through to soft or sealer, and refinish
caused by thinner penetration sensitive substrates

» Improper thinner or reducer, especially » Seal to eliminate sandscratch swelling.

a slow-dry thinner or reducer when Select thinner or reducer suitable for
sealer has been omitted existing shop conditions

» Under-reduced or wrong thinner (too » Use proper thinner and reducer for
fast) used in primer-surfacer causes primer-surfacer
“bridging” of scratches
» Do not apply coats of primer too
» Primer not well dried before application heavily
of color
» Use compatible paint systems.
» Application of undercoat too heavy

» Application of color when the original

finish is too sensitive to paint solvents
used

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Paint Defects Manual

Environmental
Contamination Description
Discolored spots in the pigments of the topcoat.
Also known as: acid rain, bird droppings, spotting, pitting, acid marks Clearcoat losing transparency and/or gloss.
Etching marks visible in the topcoat.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Contamination from agricultural and » Avoid contaminated atmosphere » Wash the vehicle very carefully with
horticultural sprays. The problem is detergent and water using a brush
seasonal/regional and affected by » Frequent washing is the best and lots of water to neutralize the
bird/insect population. The organic safeguard against unseen contamination
etching is accelerated by intensified contaminants
heat, such as from sunlight. Time » Rub affected areas with rubbing
and temperature dramatically » Maintain and protect the topcoat compound and polish
increases concentration of acid. The of the vehicle using a nonsilicone
damage is more visible on dark or containing polish or wax » In severe cases, sand the areas needed
darker colors due to heat absorption. and be sure the craters are sanded
» Immediately clean and neutralize the away completely before using primer
» Acid rain is the term given to rain contamination with mild detergent and and topcoat
containing effluents from chemical water before etching starts
industries,manufacturing, and
particularly power stations. Some of the
effluents may be acidic or alkaline in the
presence of water (e.g. sulphur dioxide
will dissolve in water to give an acidic
solution, whilst a mixture of cement
dust and water is strongly alkaline).

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Paint Defects Manual

Fish
Eyes Description
Small, crater-like opening in the finish
Also known as: poor wetting, saucering, pits, craters, cissing after it has been applied.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Improper/ insufficient surface cleaning » Precautions should be taken to remove » Apply light coats of basecoat until
or preparation. Many waxes and polishes all traces of silicone by thoroughly defect is covered
contain silicone, the most common cause cleaning the substrate
of fish eyes. Silicones adhere firmly to » If required or recommended, use fish-
the paint film and require extra effort for » Drain and clean air pressure regulator eye eliminator
their removal. Even small quantities in daily to remove trapped moisture and
sanding dust, rags can cause this type dirt. Air compressor tank should also be » In severe cases, sand the affected
of failure. drained daily areas, clean thoroughly isolate and
refinish
» Effects of the old finish/ previous repair. » Regular maintenance of the air supply
The old finish/ previous repair may
contain excessive amounts of silicone
from additives used during application.
Usually solvent wiping will not remove
embedded silicone.

» Contamination of air supply, by water

or oil

» Oil, wax, grease or silicone contamination

» Use of silicone-containing polishes or

aerosol sprays (e.g.: interior cleaners or
dressings) in proximity to the spray area

19
Paint Defects Manual

Hiding
Also known as: coverage, opacity, transparency
Description
When the filler, primer or sealer on the repair
area is visible through the topcoat.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Inadequate lighting in the spraybooth » Use recommended thinner » Allow the finish to properly dry, then
sand and refinish.
» Color was not well mixed/stirred » Install good lighting equipment

» Too much thinner was used » Verify proper spray gun setup

» Substrate’s color was not correct » Mix/stir all colors/tintings thoroughly

» Substrate not uniform (effect finishes) » Use the appropriate ValueShade™

undercoat
» Color coat has insufficient film thickness
» Spray sufficient color to obtain hiding

20
Paint Defects Manual

Lifting Description
Also known as: wrinkling, rippling, raising
Surface distortion or shriveling, while the
topcoat is being applied or while drying.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Use of incompatible materials. Solvents » Avoid incompatible materials such as » Remove finish from affected areas
in new topcoat attack old surface a thinner with enamel products, or and refinish. In very severe cases the
which results in a distorted or wrinkled incompatible sealers and primers. whole paint system must be removed
effect. to the substrate
» Don’t pile on topcoats. Allow sufficient
» Insufficient flash time. Lifting will occur flash and dry time. Final topcoat should
when the paint film is an alkyd enamel be applied when the previous coat is
and is only partially cured. The solvents still soluble or after it has completely
from thecoat being applied cause dried and is impervious to topcoat
localized swelling or partial dissolving solvents.
which later distorts final surface.
» Select thinner or reducer that is
» Improper dry. When synthetic enamel correct for the finish applied and
type undercoats are not thoroughly suitable for existing shop conditions.
dry, topcoating with lacquer can result
in lifting. » Solvent test and remove or isolate
solvent-sensitive substrates.
» Effect of old finish or previous repair.
Lacquer applied over a fresh air-dry » Avoid excessive film thickness
enamel finish will cause lifting

» Improper preparation or surface

cleaning. Use of enamel-type primer
or sealer over an original lacquer finish
which is to be topcoated with a lacquer
will result in lifting due to a sandwich
effect.

» Wrong thinner or reducer. The use of

lacquer thinners in enamel increases
the amount of substrate swelling and
distortion which can lead to lifting,
particularly when two-toning or re-
coating.

» Application of coats too heavily

» Excessive film build

21
Paint Defects Manual

Matting
Also known as: loss of gloss, dieback
Description
Loss of initial gun gloss after finish has dried.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Improper film thickness » For mild cases, sand and polish

» Follow application recommendations
» Poor airflow, high humidity on Technical Data Sheets » In extreme cases, sand and refinish

» Solvent-sensitive substrate » Close activator cans firmly after use

» Incorrect mixing, contaminated » Ensure sufficient airflow in oven and

hardener, or unsuitable thinner do not interrupt baking cycle

» Insufficient airflow in oven or

interrupted baking

22
Paint Defects Manual

Mottling
Also known as: striping, banding, shadowing, flooding,
Description
floating, misting, precipitation, blooming, bloom, bleaching
Occurs mainly in metallics, when the flakes
float together to form a spotty or striped
appearance.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Unsuitable thinner or reducer for » Select the thinner or reducer that is » Allow color coat to set-up and apply a
application conditions suitable for existing shop conditions drier double coat or two single coats,
and mix properly. In cold, damp weather, depending upon which topcoat you
» Materials not uniformly mixed use a fasterdry solvent are applying

» Spraying too wet » Stir all pigmented topcoats - especially » If the defect is only visible after the
metallics - thoroughly application of the clear, thoroughly dry
» Holding spray gun too close to work the clear, sand and refinish
» Use proper gun adjustments,
» Uneven spray pattern techniques, and air pressure

» Incorrect spray PSI or gun setup » Keep your spray gun clean (especially
the needle fluid tip and air cap) and in
» Low shop temperature good working condition

» The flash time of the basecoat was too » Do not spray metallic basecoats too
short before the clearcoat was applied wet

» Coat affected by wet or humid air/ » Keep spray gun parallel to panel
weather.
» Follow application recommendations
per the TDS.

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Paint Defects Manual

Orange Peel Description

Also known as: poor flow, poor levelling, pebbling
Uneven surface formation - much like that of
the skin of an orange.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Improper gun adjustment/ techniques. » Use proper gun adjustments, » For mild cases, sand and polish using
Too little air pressure, wide fan patterns techniques, and air pressure recommended materials and
or spraying at excessive gun distances techniques
causes droplets to become dry during » Schedule painting to avoid temperature
their travel time to the substrate and and humidity extremes » In extreme cases, sand down to
they remain as formed by gun nozzle. smooth surface and refinish, using a
» Select the thinner or reducer that is slower evaporating thinner or reducer
» Extreme shop temperature. When air suitable for existing conditions. The use at the correct air pressure
temperature is too high, droplets lose of a slower evaporating thinner or
more solvent and dry out before they reducer will overcome this
can flow and level properly
» Allow sufficient flash and dry time. Do
» Improper dry. Gun fanning before paint not dry by fanning
droplets have a chance to flow together
will cause orange peel » Allow proper drying time for undercoats
and topcoats. Not too long or not too
» Improper flash or recoat time between short
coats. If first coats of enamel are
allowed to become too dry, solvent in » Reduce to recommended viscosity with
the paint droplets of following coats will proper thinner/reducer
be absorbed into the first coat before
proper flow is achieved » Stir all pigmented undercoats and
topcoats thoroughly.
» Wrong thinner/ reducer. Under-diluted
or thinned paint with fast evaporating » Prepare and sand substrate correctly
thinners/reducers causes the atomized
droplets to become too dry before » Follow recommendations on technical
reaching the surface. Too high viscosity data sheets.

» Low shop temperature

» Too little thinner or reducer

» Materials not uniformly mixed. Many

finishes formulated with components
aid coalescence. If these are not
properly mixed, orange peel will result

» Substrate not sanded thoroughly 24

Paint Defects Manual

Peeling Description
Also known as: loss of adhesion, shelling, poor
Loss of adhesion between paint and substrate - topcoat to
bond, delamination, flaking, poor adhesion
primer and/or old finish, or primer to substrate.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Improper cleaning/ preparation. Failure » Use appropriate grits of sanding » Remove finish from an area slightly
to remove sanding dust and other material larger than the affected area
surface contaminants will stop the and refinish.
finish coat from coming into proper » Seal to eliminate sandscratch swelling.
contact with the substrate Select thinner or reducer suitable for
existing shop conditions
» Improper metal treatment
» Use proper thinner and reducer for
» Use of incompatible material for primer-surfacer
substrate
» Do not apply coats of primer too
» Materials not uniformly mixed heavily

» Failure to use proper sealer » Use compatible paint systems

» Paint film too thick » Degrease and prepare substrate

carefully
» Dry application
» Follow application recommendations
» Film was too dry when the masking per Technical Data Sheets
tape was removed

» Flash times too short

» Poor sanding of substrate or

undercoats

» Too low/too high surface temperature

during application

» Condensation on substrate due to

temperature changes

25
Paint Defects Manual

Pinholing Description
Also known as: pin holes, pock marks, pitting, pops, pin pricks
Tiny holes in the finish, putty or primer, the result of trapped
solvents, air or moisture or improper surface preparation.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Improper surface cleaning/ preparation. » Thoroughly clean all areas to be » After thorough drying of the
Moisture left on primersurfacers will painted. Be sure surface is completely affected area, sand completely
pass through the wet topcoat to cause dry before applying undercoats or smooth, reapply polyesters or
pinholing topcoats undercoats as necessary and
refinish
» Contamination of air lines. Moisture or » Drain and clean air pressure regulator
oil in airlines will enter paint while being daily to remove trapped moisture and
applied and cause pinholes during the dirt. Air compressor tank should also be
drying stage. drained daily

» Wrong gun adjustment or technique. I » Use proper gun adjustments, air

If application is too wet, or if the gun is pressure and techniques
held too close to the surface, pinholes
will occur when the air or excessive » Select the thinner or reducer that is
solvent is released during dry suitable for existing shop conditions

» Wrong thinner/ reducer. The use of » Allow sufficient flash and dry time. Do
a solvent that is too fast for shop not dry by fanning
temperature tends to make the
refinisher spray too close to the surface » Thoroughly mix polyesters
in order to get adequate flow. When
the solvent is too slow, it is trapped by » Completely sand smooth solvent pop
subsequent topcoats pores and other defects before
refinishing
» Improper drying. Fanning a newly
applied finish can drive air into the
surface or cause a skin to form, which
result in pinholing when solvents
retained in lower layers come to the
surface

» Insufficient sanding or filling of pores in

fiberglass substrates

» Insufficient mixing or isolation of

polyesters

» Solvent popping that has not been

sanded to smooth 26
Paint Defects Manual

Polishing
Marks Description
Ultra-fine scratches remaining on the coating surface from a compounding
or polishing operation. Can also be fine scratches left in the surface from
any preparation sanding performed prior to compounding or polishing.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Top coat not through-dried Prevention Techniques: » If layers are not cut through,
» Thoroughly dry top coat, if necessary thoroughly dry topcoat and re-polish
» Sandpaper too coarse re-bake
» If condition is not removed, or layers
» Unsuitable polish » Use suitable polish and equipment are cut through, thoroughly dry
topcoat, sand and refinish.
» Polishing through layers on edges » Use correct sandpaper

» Use polish, free of ammonia

27
Paint Defects Manual

Runs
Also known as: overloading, curtains, gun spits, sags,
Description
sagging, drips
Heavy application of sprayed material that
fails to adhere uniformly to the surface.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Incorrect spray viscosity, flash time, » Allow vehicle surface to warm-up to at » Wash off the affected area and let dry
technique, or film thickness least room temperature before until you can sand the affected area to
attempting to refinish a smooth surface and refinish. For solid
» Defective or incorrect spray gun set-up colors and clearcoats, sanding and
» Try to maintain an appropriate shop polishing is recommended. In the case
» Wrong thinner or reducer temperature for paint areas of a basecoat, refinishing after sanding
is necessary.
» Too much thinner or reducer » Use proper gun adjustment, air
pressure, and techniques
» Inaccurate lighting in the spraybooth,
painter is unable to apply coating » Allow sufficient flash-off and drying
correctly time in between coats

» Surface contamination by oil, grease, etc. » Select proper thinner/reducer

» Shop, surface or paint is too cold » Read and carefully follow label or
product data sheet instructions
» Low air pressure (causing lack of
atomization), holding gun too close, or » Select suitable thinner/ reducer
making too slow a gun pass
» Install accurate lighting in spray booth
» Incorrect technique of application
» Ensure that the spray gun is in good
» Paint drops from the gun working order.

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Paint Defects Manual

Slow
Drying Description
Paint takes a longer time to set up or dry than
detailed in the Technical Data Sheet.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Wrong activator » Use recommended system activators » Place the vehicle in a warmer, more
and reducers, per the Technical Data ventilated area. The drying process
» Incorrect mixing ratio Sheet may be accelerated with the
application of heat and improved
» Heavy application » Apply recommended film thickness airflow

» Incorrect reducer or activator for » Allow sufficient flash-off time between

spray conditions coats

» Poor drying conditions: too humid, » Improve spraying and/or drying

insufficient air flow or ventilation conditions

» Insufficient flash-off time between

coats

» Use of non-system activators or

reducers

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Paint Defects Manual

Solvent
Pop Description
Solvent that got out too late and could not reheal,
Also known as: Boiling, solvent boil, popping thus leaving a hole in the surface.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Solvent or air trapped in film escapes » Thoroughly clean areas to be painted » If damage is extensive and severe,
during drying leaving pop marks paint must be removed down to
» Select suitable thinner or reducer for undercoat or metal, depending on
» Incorrect viscosity, spray pressure, flash shop conditions depth of blisters; then refinish
time, or improper drying
» Allow sufficient flash and drying time. » In less severe cases, sand until smooth,
» Incorrect choice of hardeners and/or Allow each coat of primersurfacer to resurface and refinish
thinners. Use of fast-dry thinner/ flash-off naturally - DO NOT FAN
reducer, especially when the material is
sprayed too dry or at excessive pressure » Apply film at recommended thickness

» Excessive film thickness. Insufficient » Follow technical recommendations of

dry time between coats. Too heavy products in use
application of the undercoats may trap
solvents causing popping

» Incorrect drying of primer/ fillers

» Improper surface cleaning/ preparation

» Infrared facilities too close

» Baking started too soon after applying,

temperature too high

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Paint Defects Manual

Water
Spotting Description
General dulling of gloss in spots or
masses of spots.

ORIGIN AND POTENTIAL CAUSES PREVENTION TECHNIQUES REMEDY

» Washing finish in bright sunlight » Allow sufficient drying time before » Remove marks by compounding or
delivering car to customer polishing
» Droplets of water evaporating on finish
which is not sufficiently cured due to: » Wash car in shade and wipe » In severe cases, sand affected areas,
» Excessive film thickness, drying time completely dry isolate and refinish
too short
» Failure of cross linking due to » Follow technical recommendations
moisture contamination
» Unsuitable thinner » Ensure lids are tightly replaced after
using hardeners
» Do not apply water to fresh paint job
and try to keep newlyfinished car out
of rain

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