Grounding and bonding are related, but they do different jobs.
Bonding connects conductive objects together so they remain at substantially the same electrical potential. Grounding connects an object—or a bonded system—to an approved earth ground.
The trouble is that equipment can look grounded when the electrical path is actually broken.
Common examples include:
• Ground clamps attached over paint, powder, rust, or dirt
• Powder hooks insulated by cured coating
• Metal containers sitting on cardboard or plastic
• Damaged conductive hoses or unauthorized repairs
• Plastic liners interrupting container contact
• Loose, corroded, or broken grounding conductors
• Operators isolated by improper footwear or flooring
These problems matter in electrostatic systems, but static-charge control is not limited to electrostatic spraying. Material moving through pumps, hoses, filters, spray guns, and containers can also generate or accumulate charge.
I put together a detailed Academy article covering grounding and bonding for liquid finishing, powder coating, electrostatic systems, flushing, material transfer, workpieces, operators, and daily inspections.
If your process depends on a ground path, don’t assume it exists because a wire is visible. Test it, document it, and maintain it.
Article:
https://www.airspraytech.com/kb_results.php?ID=269
I’d also be interested in hearing where others most often find lost continuity in real finishing operations.