Specialized Corrosion & Coatings Testing Services
GPI Labs provides dedicated laboratory programs for widely used corrosion standards, coating-failure investigations, and infrastructure applications. Use the links below to go directly to the service most relevant to your project.
Corrosion & Environmental Exposure Testing
GPI Labs evaluates coatings, metals, components, assemblies, and protective systems under controlled corrosive and environmental exposure conditions. Programs range from ASTM B117 neutral salt spray, ASTM G85 modified salt spray testing, ASTM D5894 cyclic corrosion and weathering testing, humidity, gas corrosion, immersion, offshore coating qualification testing, pipeline materials, coating, and corrosion testing, water and wastewater infrastructure testing, and project-specific exposures.
Learn About Materials, Protective Coatings & Corrosion
ASTM B117 and ASTM G85 Salt Fog Testing
GPI Labs provides ASTM B117 salt spray testing services and related salt fog exposures for coated panels, metals, components, and assemblies. We review your governing specification with you to confirm the required method, exposure duration, specimen preparation, inspections, and evaluation criteria.
- Neutral Salt Spray: Continuous salt fog exposure for comparative corrosion screening and coating evaluation under ASTM B117 and ISO 9227 NSS.
- Acetic Acid Salt Spray: Acidified salt fog exposure under ISO 9227 AASS and ASTM G85 Annex A1.
- Copper-Accelerated Acetic Acid-Salt Spray: Aggressive acidified salt fog testing under ASTM B368 and ISO 9227 CASS.
- Modified Salt Spray and Prohesion: Modified salt fog exposures under ASTM G85, including Annex A5 programs.
Cyclic Corrosion Testing
Cyclic corrosion methods combine controlled spray, wetting, humidity, drying, temperature, and ambient transitions to reproduce more complex service environments than continuous salt fog alone.
- Industry Cyclic Corrosion: SAE J2334.
- General Motors: GMW 14872.
- Ford: Ford CETP 00.00-L-467.
- Volkswagen Group: VW PV 1200 and VW PV 1210.
- BMW: BMW GS 95024.
- Volvo: Volvo VCS 1027 and Volvo VCS 1029.
- Mercedes-Benz: Applicable DBL-series corrosion programs.
- Additional Manufacturer-Specific Programs: Testing to the exact OEM procedure supplied with your project.
Humidity and Condensation Testing
- High-Humidity Exposure: ASTM D1735 and ASTM D2247.
- Condensation Exposure: ASTM D4585 and ISO 6270, including ISO 6270-1.
- Cleveland Condensation: Continuous condensation exposure for evaluating coating resistance in warm, moisture-saturated conditions.
Gas Corrosion and Atmospheric Simulation
- Sulfur Dioxide and Kesternich Testing: Industrial atmospheric corrosion exposure under ASTM G87, DIN 50018, ISO 3231, and ISO 6988.
- Mixed Flowing Gas Testing: Low-concentration pollutant exposure for electrical connectors, contacts, terminals, and assemblies under IEC 60068-2-60, EIA-364-65, ASTM B827, and ASTM B845.
- Powered Electronics Testing: Mixed flowing gas exposure of energized electrical connectors, circuit boards, control modules, sensors, relays, and other live electronic assemblies to evaluate corrosion-related performance under controlled atmospheric conditions.
- Atmospheric Air and Gas Screening: Environmental classification and corrosion evaluation for telecom equipment, automotive electronics, connectors, and terminals under ASTM B810 and ISA 71.04.
Water, Wastewater, Immersion & Severe-Service Exposure
GPI Labs provides specialized water and wastewater coating, lining, and materials testing for infrastructure applications including sewer systems, manholes, wet wells, pipe, tanks, treatment structures, and other assets exposed to immersion, condensation, severe wastewater environments, and freeze/thaw conditions. Testing capabilities include ASTM G210, ASTM D870, ASTM D2247, ASTM D6944, and ASTM D2243.
- Severe Wastewater Exposure: ASTM G210 testing for protective coatings, linings, and materials exposed to severe wastewater liquid and simulated sewer-gas headspace conditions.
- Water and Liquid Immersion: ASTM D870 and ISO 2812-2.
- Chemical and Household Fluid Resistance: ASTM D1308.
- Cathodic Protection and Disbondment: Evaluation of pipeline coatings and structural protective systems under ASTM G8 and ASTM G42.
- Atlas Cell Immersion: Severe-service coating and lining evaluations using specialized immersion cell configurations.
Offshore Coating Qualification Testing
Offshore protective coating systems can require combinations of cyclic corrosion, UV/condensation weathering, seawater immersion, thermal cycling, adhesion testing, cathodic disbondment, and post-exposure coating evaluation. GPI Labs supports qualification programs for atmospheric, splash-zone, submerged, and ballast-tank service using applicable AMPP/NACE, ISO, NORSOK, ASTM, and project-specific requirements.
ISO 12944 Protective Coating Qualification
GPI Labs supports complete protective paint system qualification programs, including test-panel preparation, controlled coating application, specified laboratory exposures, post-exposure evaluation, and technical reporting. For C2–C5 atmospheric environments and Im1–Im3 immersion categories, see our ISO 12944-6 testing services. For testing specifically to ISO 12944-9, including CX offshore atmospheres, Im4 submerged service, and splash-and-tidal-zone exposure, see our ISO 12944-9 testing services. For broader offshore qualification programs combining ISO, AMPP/NACE, NORSOK, cathodic disbondment, seawater immersion, thermal exposure, and coating evaluation, see our offshore coating qualification testing services.
Specialty Environmental Exposures
- Water Mist Exposure: GM 9103P.
- Moisture and Rain Exposure: JIS 0203.
- Water Impact Testing: IEC 60068-2-18.
- Project-Specific Programs: Custom exposure sequences, combined environments, modified corrosion cycles, walk-in environmental exposures for oversized components and assemblies, and application-specific validation programs.
Weathering & UV Testing
Accelerated weathering programs evaluate how coatings, polymers, plastics, composites, and finished products respond to ultraviolet exposure, condensation, moisture, temperature, and combined environmental cycling.
Fluorescent UV Exposure
- General Fluorescent UV Weathering: ASTM G154.
- Coating Weathering: ASTM D4587.
- Plastic Weathering: ASTM D4329.
- International Weathering Programs: ISO 16474.
- Automotive Exterior Materials: SAE J2020.
Condensation and Moisture Cycling
UV exposure can be combined with controlled condensation, moisture, temperature, and dark-cycle conditions to evaluate gloss loss, color change, chalking, cracking, embrittlement, adhesion loss, and other forms of weathering-related degradation.
Natural Outdoor Weathering
Outdoor exposure rack testing evaluates how coatings, plastics, composites, and other materials perform under real-world sunlight, temperature, moisture, and seasonal weather conditions over time.
Combined Cyclic Weathering
- UV and Corrosion Cycling: ASTM D5894 testing alternates fluorescent UV/condensation exposure with ASTM G85 Annex A5 dilute-electrolyte fog/dry cycling for painted metal and protective coating systems.
- Protective Coating Durability: Combined exposure and evaluation programs supporting applicable ISO 12944 requirements.
- Custom Sequential Exposures: Programs may combine UV, condensation, salt fog, humidity, immersion, drying, and post-exposure performance evaluations.
Post-Weathering Evaluation
- Color change and instrumental color measurement.
- Gloss retention and gloss loss.
- Chalking, cracking, checking, flaking, and blistering.
- Adhesion retention following weathering exposure.
- Comparative visual and instrumental product evaluations.
Materials & Coatings Performance Testing
GPI Labs measures the mechanical, visual, structural, and durability properties of paints, coatings, adhesives, metals, fasteners, and finished systems before or after environmental exposure.
Adhesion Testing
- Cross-Cut and Tape Adhesion: ASTM D3359 and ISO 2409, including Method A X-cut and Method B cross-hatch evaluations.
- Pull-Off Adhesion: ASTM D4541 and ISO 4624.
- Knife Adhesion: ASTM D6677.
Abrasion, Impact, and Hardness
- Taber Abrasion: ASTM D4060.
- Falling Sand Abrasion: ASTM D968.
- Impact Resistance: ASTM D2794.
- Pencil Hardness: ASTM D3363.
- Durometer Hardness: Shore D and other appropriate durometer measurements.
- Gravelometer Chip Resistance: SAE J400.
- Scrubability and Washability: ASTM D2486.
Optical Properties
- Instrumental Color Measurement: ASTM D2244 and ASTM E1349, including CIE L*a*b* color values and color difference calculations.
- Specular Gloss: ASTM D523 measurements at appropriate 20-degree, 60-degree, and 85-degree geometries.
Post-Exposure Coating Evaluation
- Corrosion Creep and Creepback: ASTM D1654 and ISO 12944-6 Annex A.
- Blistering: ASTM D714 and applicable ISO 4628 methods.
- Rusting: ASTM D610 and ISO 4628-3.
- Cracking, Flaking, and Related Defects: ASTM D661, ASTM D772, and applicable ISO 4628 methods.
- Filiform Corrosion: ASTM D2803 and ISO 4628-10.
When coating damage is being investigated rather than simply rated after exposure, GPI Labs can combine these evaluations with microscopy, cross-section analysis, adhesion testing, FTIR, chemical characterization, and controlled re-exposure through our coating failure analysis and laboratory investigation services.
Corrosion Rate Documentation
GPI Labs can document corrosion progression through periodic inspection, weight-loss measurements where applicable, visual evaluation, photographic documentation, and other methods specified for your project to support comparative material evaluations and long-term exposure studies.
Structural and Fastener Testing
- Structural Bolting: Slip coefficient and creep resistance testing for structural bolted assemblies in support of applicable Research Council on Structural Connections (RCSC) requirements.
- Custom Mechanical Evaluations: Project-specific fixtures, loading arrangements, assemblies, and performance criteria.
Analytical Chemistry & Failure Investigation
GPI Labs provides analytical and forensic testing to identify material composition, verify product properties, compare formulations, investigate contamination, and support coating failure analysis and laboratory investigations.
Chemical and Compositional Testing
- VOC Profiling: EPA Method 24 and ASTM D3960.
- Exempt Volatiles: Gas chromatography under ASTM D6133.
- Volatile and Nonvolatile Content: ASTM D2369.
- Volume Nonvolatile Matter: ASTM D2697.
- Water Content: Gas chromatography under ASTM D3792 or Karl Fischer analysis under ASTM D4017.
- Pigment Content: Low-temperature ashing under ASTM D3723 or solvent extraction under ASTM D2371.
- Metallic Zinc Content: ASTM D521.
Physical Property Testing
- Stormer Viscosity: ASTM D562.
- Brookfield Viscosity: ASTM D2196.
- Dip Cup Viscosity: ASTM D4212.
- Fineness of Dispersion: ASTM D1210.
- Density and Weight per Volume: ASTM D1475.
- Flash Point: Pensky-Martens closed-cup testing under ASTM D93.
- Dry and Cure Time: ASTM D1640.
- Sag Resistance: ASTM D4400.
- Hiding Power and Contrast Ratio: ASTM D2805.
- Adhesive Flow and Bonding Properties: ASTM D1338.
Failure Analysis and Forensic Characterization
- FTIR Analysis: Fourier-transform infrared spectroscopy under ASTM E1252 using ATR, KBr pellet, or other appropriate sample preparation techniques.
- Elemental Profiling and Targeted Metals Screening: Comparative elemental analysis selected according to the material, suspected contaminant, and investigation objective.
- Microscopy and Cross-Sectional Evaluation: Examination of coating layers, interfaces, corrosion products, defects, contamination, and material damage.
- Comparative Product Characterization: Side-by-side evaluation of failed, retained, reference, and competitive materials.
Coating Failure Analysis
When a coating or lining fails in service, GPI can combine microscopy, cross-section evaluation, film-thickness measurement, adhesion testing, FTIR, chemical analysis, standardized coating-condition ratings, and controlled laboratory exposure to investigate the likely cause.
Investigations can address blistering, delamination, corrosion, adhesion loss, cracking, abnormal film build, contamination, application or cure problems, specification deviations, and other coating-system failures.
Heavy Metals & Elemental Analysis
GPI Labs provides metals and elemental analysis for paints, coated materials, soils, abrasives, industrial materials, waste streams, wastewater, and other compatible sample matrices.
Paints and Coated Materials
Metals and elemental analysis of paints, coatings, coated scrapings, and related product materials using sample preparation and analytical techniques selected for the material and project objective.
Soils and Selected Environmental Samples
Metals analysis of soils and compatible environmental samples using appropriate digestion, extraction, and instrumental methods based on the sample matrix and requested analytes.
Abrasives and Industrial Materials
Targeted metals screening and comparative elemental analysis for blasting abrasives, raw materials, process materials, residues, and other compatible industrial samples.
Waste Streams and Wastewater
- Metals analysis of compatible waste-stream samples.
- Wastewater chemistry and targeted metals evaluations.
- Paint filter residue analysis.
- Material and waste characterization programs built around your requirements.
- Comparative and targeted elemental screening for applicable sample matrices.
Abrasive Quality Control & Surface Cleanliness
GPI Labs evaluates blasting abrasives and prepared steel surfaces to help verify abrasive quality, identify contamination, and confirm surface cleanliness before coating application.
Abrasive Qualification
- Recycled Ferrous Metallic Abrasives: Testing supporting applicable SSPC AB 2 requirements.
- Newly Manufactured or Reprocessed Metallic Abrasives: Testing supporting applicable SSPC AB 3 requirements.
- Project-Specific Abrasive Programs: Incoming material, supplier qualification, recurring quality control, and comparative abrasive evaluations.
Contamination and Physical Screening
- Particle size distribution and sieve analysis.
- Water-soluble contaminant evaluation through conductivity testing under ASTM D4940.
- Oil contamination checks.
- Moisture content monitoring.
- Heavy metals and elemental screening.
- Comparative evaluation of new, reclaimed, and in-service abrasives.
Surface Cleanliness Verification
Soluble salt contamination on prepared steel can interfere with coating adhesion and contribute to osmotic blistering or premature corrosion. GPI performs Bresle patch extraction and conductivity-based evaluation under ISO 8502-6 and ISO 8502-9.
Quality Control Applications
- Incoming abrasive inspection.
- Blast media supplier qualification.
- Recurring batch or lot verification.
- Field and shop surface cleanliness validation.
- Pre-coating soluble salt confirmation.
- Failure investigation support involving contaminated surfaces.
Technical Sample Preparation & Coating Application
GPI Labs can prepare the substrates, test panels, assemblies, and coated specimens required for a complete laboratory program. Services range from material sourcing and cutting to blasting, custom fabrication, professional coating application, and presentation-quality show panels.
Panel Production and Substrate Sourcing
- Steel test coupons and panels.
- Aluminum substrates.
- Stainless steel substrates.
- Specialty alloys and materials specified for your project.
- Custom cutting, sizing, drilling, scribing, and identification.
- Matched panel sets for comparative or multi-stage programs.
Surface Preparation
- Blast cabinet preparation using mineral abrasives.
- Steel abrasive blasting.
- Mechanical hand-tool preparation.
- Power-tool cleaning and detailing.
- Anchor profiles specified for your project.
- Preparation to applicable AMPP, NACE, SSPC, ISO, or project-defined cleanliness requirements.
Custom Test Geometries and Assemblies
- Welded assemblies and weldments.
- Active weld beads.
- Bolted stacks and bolted joint assemblies.
- Edge-retention and sharp-edge configurations.
- Overlapping seams and crevice geometries.
- Components and finished assemblies you supply.
- Custom fixtures and application-specific sample configurations.
Precision Paint and Coating Application
- Conventional pressure-pot spray application.
- Automated coating application.
- Brush and roller application.
- High-pressure airless spray application.
- Heated plural-component application.
- Controlled wet-film and dry-film thickness targets.
- Multi-coat systems with specified recoat and cure intervals.
High-Finish Show Panels
Uniform, presentation-quality coated panels can be prepared for trade shows, customer presentations, product demonstrations, internal review, marketing photography, and comparative finish displays.
Batch Quality Assurance & Product Evaluation
GPI Labs supports manufacturers and product owners that need independent verification of incoming materials, production batches, finished products, competitive products, or supplier compliance.
Batch and Lot Verification
- Routine production batch evaluation.
- Incoming raw material or supplier verification.
- Retained sample comparison.
- Investigation of suspected off-specification material.
- Independent confirmation of reported product properties.
- Recurring quality control programs with consistent test methods.
Product Qualification
- Qualification against your specification.
- Evaluation against ASTM, ISO, SAE, OEM, DOT, or agency requirements.
- New product development and formulation screening.
- Supplier approval and alternate material qualification.
- Performance verification before commercialization or field deployment.
Competitive Product Evaluation
- Side-by-side product performance testing.
- Comparative corrosion and weathering exposures.
- Comparative adhesion, abrasion, impact, hardness, color, and gloss.
- Physical and chemical property comparisons.
- Analytical fingerprinting and compositional comparison.
- Documented evaluation of performance differences.
Specification and Compliance Testing
Send GPI Labs your specification and project requirements. We can identify the applicable laboratory procedures, prepare the required samples, perform the testing, document the results, and provide reporting for the defined scope.
Integrated Testing Programs
Batch quality assurance and product evaluation programs can combine multiple GPI capabilities into one coordinated project, including:
- Substrate sourcing and panel production.
- Controlled surface preparation.
- Professional coating application.
- Baseline physical and analytical characterization.
- Corrosion, weathering, humidity, immersion, or chemical exposure.
- Post-exposure adhesion and appearance evaluation.
- Failure analysis or comparative analytical testing.
- Photographic documentation and final laboratory reporting.
Discuss Your Testing Requirements with GPI Labs
Send us your test specification, product information, sample type, coating system, exposure requirement, quality concern, or failure investigation need. Our laboratory team will help identify an appropriate testing and sample preparation program.