Issues like fading, chalking, peeling, and flaking are not just cosmetic; they compromise the protective layer of doors, exposing them to environmental damage.

These failures often arise due to poor surface preparation, incorrect application techniques, environmental conditions, and other factors.

Understanding the root causes is essential for facility operators diagnosing problems and contractors aiming to avoid costly and labor-intensive repainting.

Common Causes of Paint Failure

• Incorrect Paint Specification: Using the wrong type of paint or primer for the surface, such as applying stucco paint on metal, leads to early failure.
• Inadequate Surface Preparation: Failing to clean the surface properly—removing chalk, dirt, oil, and other contaminants—before repainting compromises adhesion and leads to peeling and flaking.
• Improper Surface Abrasion: Smooth or glossy surfaces require abrasion to create a profile for the coating to adhere. Not sanding or abrading leads to poor adhesion.
• Wrong or Missing Primer: Applying paint without the appropriate primer can cause bonding issues.
• Poor Weather Conditions: Painting in unsuitable conditions, such as extreme heat, cold, or humidity, leads to imperfections like pinholes, orange peel, and stippling.
• Over-Reducing the Coating: Adding too much reducer compromises the performance of the paint.
• Uneven Film Thickness: Applying an uneven or inadequate paint layer results in premature wear and surface defects.
• Excessive Paint Layers: After multiple layers, typically five to six coats, the risk of failure significantly increases.
• Delaying Repainting: Allowing the substrate to age too long before repainting can lead to early paint failure, exposing the door to further damage.

Surface Not Adequately Cleaned

Failure to Remove Dirt, Oil/Grease, etc.

This problem is similar in nature to the problems of painting on chalk. For the best adhesion, you want to use the proper paint, or primer and paint combination, directly on top of the metal or well-bonded previous coatings. Anytime there is something between the solid foundation and your paint, the applied paint will layer on top of this substance, be it dirt, chalk, grease, previous applications of silicone or waxy substances, and so on.

This can result in areas where the paint will peel, bubble, crack, or show pebbling or roughness due to the trapped debris. Before painting, the door must be fully clean, including the removal of grease and chalk with something like Zap-It! Chalk & Grime Buster or an equivalent product.

A note for painters: be sure to clean difficult or hard-to-reach areas like the tops and bottoms of doors, as we have seen plenty of failures at these spots due to incomplete cleaning.

Insufficient Surface Profile

Failure to Sand Smooth, Slick, or Glossy Surfaces

In the first image, you can see the door was painted without proper surface preparation, mainly not abrading the surface. The glossiness of the underlying 'old' coating is still visible with no evidence of sanding or 'scratching' to help the new coat bind to the surface. As a result, the paint is breaking loose due to the expansion and contraction of “freeze-thaw” cycles.

In the second image, you can see that the front and back of the curled top coat are the same color, indicating that in this case, no primer was used.

Zap-It Chalk & Grime Buster for Storage Roll Doors

Powerful chalk remover and cleaner for door refinishing prep work.

• Removes chalk (oxidized paint), grease and grime in preparation for refinishing roll-up doors
• Cuts through chalk and grease to make prep work faster
• Economically priced

Learn More

Improper Application Method or Technique

Inadequate or Uneven Film Thickness

In addition to poor preparation, improper application techniques can lead to a range of issues like orange peel, pinholes, stippling, dripping, and sagging. These imperfections can compromise both the coating’s appearance and durability.

Key Application Issues to Avoid:

Spray Gun Settings:

• High Pressure: Over-atomizes the paint, creating a textured finish.
• Low Pressure: Causes large droplets and stippling.
• Incorrect Spray Tip Size: The wrong tip can lead to poor atomization or uneven application.

Spray Technique:

• Distance from Surface: Spraying too close causes uneven buildup, while spraying too far can cause the paint to dry prematurely.
• Inconsistent Speed: Moving the sprayer unevenly results in inconsistent texture.
• Improper Paint Viscosity: Follow manufacturer guidelines for thinning to ensure proper atomization.

Environmental Conditions:

• Temperature & Humidity: Extreme conditions can cause rapid drying or stippling.
• Wind & Contamination: Dust or debris on the surface can cause imperfections in the paint.

Equipment Maintenance:

• Old or Clogged Spray Tips: Worn or clogged tips result in uneven application and texture issues.

Click here to review a PDF with Airless Spraying Guidelines.

Existing Paint Aged Too Long Before Repainting

As paint weathers, it becomes thinner and more brittle. When paint is allowed to exceed its life expectancy before being recoated, the risks associated with repainting increase significantly. Aging paint loses its ability to adhere properly to the underlying surface, leading to potential peeling, cracking, and other failures.

Painting over a brittle coating presents numerous opportunities for failure. The old paint may not be securely adhered, causing the new coating to pull on the weakened surface. This can lead to flaking, cracking, or shedding particles into the new layer, compromising its integrity and appearance.

Before applying a new coat, thorough preparation is essential, including cleaning, sanding, and possibly priming. These steps ensure proper adhesion and extend the life of the new coating. Neglecting this preparation can result in premature paint failure, requiring more frequent maintenance or even complete removal and reapplication.

Application of Too Many Layers of Paint

Each time you paint, the paint contracts as it dries and continues to contract as it ages. These contractions put pressure on the layers beneath. If there's only one previous layer, it may not be a big issue. But older doors may accumulate many layers of paint over years of use. The newest layer contracts and adds stress to the older layers, which may be more brittle or have weaker adhesion. Typically after 5 – 6 coats of paint applied over a period of years the risk of failure increases significantly.

Attempting to Re-Catalyze Paint

Adding Solvent After Catalyzation Has Begun

Paints that use a catalyst undergo a chemical binding process and have a pot life. Pot life is the period during which the paint can be applied effectively before it becomes too thick, sticky, or begins to solidify in the container. After the pot life expires, the paint can no longer be applied smoothly.

Sometimes painters realize they need more time and attempt to extend the pot life by adding solvent or even more catalyst. However, adding solvent to paint that is already catalyzing will not work because the paint has started to harden due to the chemical reaction. Once catalyzation begins, the paint is in the process of becoming solid. Introducing more solvent or catalyst can disrupt the curing process, leading to issues like poor adhesion, rough texture, or weak spots in the coating, ultimately compromising the paint's performance.

Disclaimer: The information provided in the Self-Storage Learning Center is for general informational purposes only. While we strive for accuracy, All From 1 Supply makes no guarantees regarding the completeness or reliability of the information. Use of this content is at your own discretion, and we encourage independent verification before making decisions based on the material.

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