7 Fundamental Reasons You Can’t Afford to Ignore
For more than 25 years, Crescent PPG has been solving one of the most persistent problems in industrial environments: the failure of acid and alkali-resistant linings. Despite advancements in materials and technology, failures still occur—and almost always for the same seven fundamental reasons.
In our pursuit of “new and advanced,” we often overlook the basics. But as experience has shown, ignoring fundamentals leads to costly downtime, safety risks, and expensive repairs. Let’s break down the 7 most common causes of lining failure and how you can avoid them.

1. Wrong Lining Material

Choosing the wrong material is the fastest route to failure.

• Example: An epoxy lining was applied to a tank storing hot caustic solution. Epoxy cannot withstand high heat or caustic chemicals. Within weeks, the lining blistered and dissolved.
• Lesson: Always match lining material to the chemical environment and operating conditions.

2. Application Mistakes

Even the best material fails if applied incorrectly.

• Example: Installers ignored mixing ratios and applied the lining unevenly. Pinholes and bubbles formed, allowing chemicals to seep through.
• Lesson: Strict adherence to manufacturer guidelines and skilled applicators are non-negotiable.

3. Poor Surface Preparation

Surface preparation is the foundation of adhesion.

• Example: A plant applied a new lining over partially removed old coating. The new lining peeled off in sheets within months.
• Lesson: Proper cleaning, blasting, and preparation ensure long-term bonding.

4. Lack of Inspections

Small defects become big failures when ignored.

• Example: A pipeline crack went unnoticed for years, allowing chemicals to leak and damage a large section.
• Lesson: Routine inspections catch minor issues before they escalate.

5. Insufficient Curing Time

Rushing the process undermines durability.

• Example: A polymer plant returned a lined vessel to service after only 6 hours of curing. The under-cured lining blistered and disbonded within weeks.
• Lesson: Respect curing times—shortcuts cost more in the long run.

6. Temperature Fluctuations

Exceeding design limits weakens linings.

• Example: A vessel rated for 60°C experienced a process upset at 90°C. The lining softened and disbonded.
• Lesson: Always account for potential temperature spikes when selecting materials.

7. Chemical Attack

Unconsidered chemicals can silently destroy linings.

• Example: Wastewater contained traces of an aggressive solvent not factored into the lining design. Over time, the solvent penetrated and dissolved the lining from the backside.
• Lesson: Comprehensive chemical analysis is essential before lining selection.

The Bottom Line

Failures are rarely due to exotic causes—they stem from overlooked fundamentals. By focusing on material selection, application discipline, surface preparation, inspections, curing, temperature control, and chemical analysis, industries can dramatically reduce lining failures.
At Crescent PPG, we believe that getting the basics right is the key to long-term reliability. Advanced solutions matter, but fundamentals are what keep your operations safe, efficient, and cost-effective.