Coil-coated samples of electrogalvanised steel were submitted to uniaxial, biaxial and plane strain of various magnitudes and tested by electrochemical impedance spectroscopy (EIS). A good correlation was encountered between the coating resistance and the equivalent plastic strain. Microscopic inspection of the coatings suggests that the decrease in the coating resistance is a consequence of defects originated by cracks on the phosphate and by loss of adhesion at the polymer/pigment interface. (C) 2004 Elsevier Ltd. All rights reserved.