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Coatings QC

Holiday Test

A holiday test is an electrical inspection that locates discontinuities — pinholes, voids, thin spots — in a nominally continuous coating. A detector applies a voltage across the film; where current passes to the substrate, the film is breached, and the spot is marked for repair.

Why holidays matter

In immersion and buried service, a single pinhole concentrates the entire corrosive demand of the environment on a point of bare metal — the small-anode configuration that perforates fast. A lining that is 99.99 % continuous is not "almost right"; it is a lining with a scheduled failure site. Holiday testing exists because visual inspection cannot see these defects.

Low voltage or high voltage

Low-voltage wet-sponge testing suits thin films: a damp sponge and a modest voltage detect breaches through conductive contact. High-voltage spark testing suits thick linings and pipeline coatings: a pulsed voltage — set according to the coating thickness and the test standard your specification cites — jumps a spark at breaches. Voltage selection is not a detail: too low misses defects, too high can create the very pinholes it is meant to find in a marginal film.

When to require it

For tank linings, immersion service and buried or wrapped piping, a holiday test at handover — and after any repair — should be a standing requirement, with the test standard, voltage basis and repair-and-retest loop written into the specification.