In the preparation of surface coatings made of conductive composites consisting of conductive particulate fillers in a soft matrix, cracks will develop with increase of the particulate loading, which is believed to be related to the nucleophilic addition reaction between glycidyl end-capped poly (bisphenol A-co-epichlorohydrin) and isophorone diisocyanate molecules. This curing reaction is responsible for the generation of crosslinking network throughout the coatings. The influence of solid particle loading on the chemical reaction may be described as a volume-excluded effect, that is, the high solid particle loading will occupy the space between the functional groups thus preventing the chemical reaction to take place. As a direct consequence, the cross-linking network cannot develop properly due to the insufficiency of curing reaction. This will lead to the generation of cracks, as was supported by FT-IR analysis in this work. In the preparation of surface coatings made of conductive composites consisting of conductive particulate fillers in a soft matrix, cracks will develop with increase of the particulate loading, which is believed to be related to the nucleophilic addition reaction between glycidyl end-capped poly -co-epichlorohydrin) and isophorone diisocyanate molecules. This influence of solid particle loading on the chemical reaction may be described as a volume-excluded effect, that is, the high solid particle loading will occupy the space between the functional groups thus preventing the chemical reaction to take place. As a direct consequence, the cross-linking network can not develop properly due to the insufficiency of curing reaction. This will lead to the generation of cracks, as was supported by FT-IR analysis in this work.