Author:
Cortney Chalifoux | Program Director | cortney.chalifoux@pondco.com
Nothing is built to last forever. Over time, exposure to the elements and other corrosive environments will cause assets to rust or crack until, eventually, they become unusable. Certain industries such as marine, oil and gas, transportation, and construction are particularly vulnerable to these challenges. Investing in a reliable industrial coating protects assets from corrosion and significantly extends their lifespan.
Coatings vs. Paint: What’s the Difference?
Industrial coatings might look the same as paint but the two are quite different. The term “paint” generally applies to the commercial and domestic markets, where its primary function is for aesthetic or design purposes.
In industrial settings, important assets might be exposed to harsh environments that pose risks to their integrity. An industrial coating applied on the outside helps to seal the asset from wind, water and other corrosive elements.
Not all coatings are created equally, but they are comprised of three main ingredients: resins, pigments and solvents.
Resin: The binder that holds pigment particles together. This can be thought of as the “glue” of the coating. The resin’s main role is to enhance the strength, durability and chemical resistance of the final film. Resins are also used to differentiate types of coatings (e.g. epoxy vs. polyurethane).
Pigment: Using one or more fine powders, pigments give coatings their color. More than that, pigments also improve resistance to weather and corrosion, enhance adhesion, and can help control moisture.
Solvent: This final ingredient is a liquid chemical that dissolves the pigments and resin into the coating. Solvents also control the viscosity of the coating, allowing it to be applied smoothly and evenly. The chemical ingredients in each solvent vary, so more than one may be used in a coating depending on its purpose.
Other additives may be incorporated into the formula to improve specific properties, such as agents to enhance UV resistance, anti-fungal capabilities, or moisture repellency.
The Layers of a Coating System
Rather than thinking of each layer as a single coat, consider that each layer is part of a system, with each layer working in unison. Beyond just the coating material, the system also refers to the requirements needed to prepare a surface for coating, the application method and number of coats, the order in which each layer needs to be applied, and the thickness of each coat.
The substrate refers to the bare surface where the coating will be applied (such as metal, wood or plastic). To prepare a substrate for coating, the surface needs to be clean and free of any grease or old coatings. Roughening the surface may be necessary to ensure the coating adheres properly and is a suitable bonding surface.
The primer is the first layer applied to the substrate. The purpose of a primer is adhesion. If the primer does not stick to the substrate the entire system will fail.
The intermediate layer is applied to serve many functions which vary based on its chemical properties. It can increase the strength of the film, enhance chemical resistance, provide additional adhesion, and be a “tie-coat” between chemically incompatible primers and topcoats.
The topcoat is the final layer of the coating system. Offering protection from chemicals and harsh weather, the topcoat also imparts aesthetic qualities and resistance to abrasion and UV light.
Each layer works together to form a protective barrier. Skipping a step or using incompatible materials can cause the whole system to fail. This holistic process enhances the long-term durability and effectiveness of the coating system.
Choosing the Right Application
Different assets have different coating requirements. As such, there are several ways to apply coatings:
Spray: This is the most common method for applying coatings to large surfaces. Spray coatings offer even coverage and fast application.
Brush: Used for cutting in and touching up where precise control is needed. Common applications for brush coatings are in tight spaces or on assets with tight corners.
Roller: Similar to spray application, rollers evenly distribute coatings across flat surfaces, providing a consistent film thickness. This is an efficient way to apply coatings on long, continuous surfaces without the risk of overspraying or wasting materials.
Dip: These types of coatings are done by immersing individual parts in a liquid coating bath. This method is ideal for small or complex components.
Powder: This specialized process requires the coating surface to be electrically conductive, making metals a suitable substrate.
Considering the asset’s environment is an important step to delivering a successful end product. Spraying or rolling is best suited for large walls or infrastructure, while brush or dip methods are ideal for smaller, more detailed components.
Coatings that Weather All Storms
An important step in choosing the right application is understanding the environment that the asset will be exposed to. Coating needs may vary based on where the asset is located, exposure to weather or high temperatures, abrasion, chemicals, moisture, and more.
Epoxy coatings are one of the most widely used types of industrial coatings due to the combination of resins that create a strong material resistant to liquids, chemicals, abrasion and moisture. Used on anything from concrete floors to pipes and tanks, to boats and marine environments, epoxy coatings are renowned for their ability to bond strongly with various substrates.
Polyurethane coatings have grown in popularity for being similarly resistant to abrasion, chemicals, and moisture. One of the distinct advantages of polyurethane is its layered application process and ability to build up layers as needed. In addition to being extremely resilient to scratches and rusting, these coatings can withstand extreme temperatures, making them ideal for marine, automotive and aerospace applications.
Silicone coatings are known for their excellent resistance to weather, ultraviolet light, and high temperatures, making them a popular choice for corrosion protection in direct sunlight. Unlike epoxy or polyurethane coatings, silicone maintains its flexibility and performance under prolonged exposure to intense heat and UV radiation. This makes silicone an ideal choice for roofing, industrial chimneys, and other outdoor assets frequently exposed to extreme conditions.
Investing in a Coatings Inspector
Corrosion is expensive. A 2013 study by NACE International shows that the global cost of corrosion is estimated to be US$2.5 trillion, which is equivalent to 3.4% of the global GDP. One way to significantly reduce the impacts of corrosion is through regular coatings inspections.
A coatings inspector examines industrial coatings during application and reports whether the coatings were applied in accordance with the specifications and established contract documents. This process can serve either as quality assurance (for the owner or operator) or quality control (for the applicator).
Pond is one of the few firms worldwide to hold a QP5 accreditation from the Association for Materials Protection and Performance (AMPP). To acquire the accreditation, AMPP evaluates an inspection company’s ability to provide consistent quality inspections to support both the owner and the coating application company.
A QP5 accreditation is the highest level of quality inspection due to the rigorous program material that includes regular maintenance training for inspectors, quality and procedural standards, corporate internal auditing of inspection records, and accountability.
This investment into industry standards and best practices enables Pond to provide exceptional quality that is backed by proven processes, procedures, and organizational resources.
Pond’s Coatings Program
Pond’s team of AMPP-certified coatings inspectors, specialists and professional engineers provide services for all types of systems, tanks, pipelines, pressure vessels, and structures. Our team’s specialized knowledge enables us to easily uncover coating and mechanical integrity risks and develop the best maintenance practices for continued integrity. Pond’s vast experience provides value at all stages of the project scope, with in-house protective coatings specialists trained in coatings, metallurgical, and integrity technologies. Learn more about Pond’s Coatings program.