A small-scale industrial coating manufacturer located near Brisbane approached us after receiving repeated complaints of rust appearing just 6 months after applying their budget outdoor metal primer. The issue threatened client trust and repeat business.

We began by conducting corrosion analysis and salt spray testing, which revealed that the anti-corrosive additives used were underdosed and ineffective under prolonged outdoor exposure.

To address this, we:

• Replaced generic zinc phosphate with modified zinc molybdate, offering improved corrosion inhibition, especially in humid and coastal environments.

• Adjusted the pigment volume concentration (PVC) to enhance the coating’s barrier properties and film integrity.

• Implemented a two-layer coating system, combining a reformulated primer with a compatible topcoat to achieve optimal film thickness and sealing performance.

As a result, the client’s product line saw a dramatic improvement in both lab and field performance—extending durability and restoring customer confidence.