How to Choose Protective Coatings for Industrial Equipment

Several specific qualities are often important for the optimal performance and longevity of various pieces of industrial equipment, and protective coatings are often near the top of any such list. What are protective coatings, which kinds of coatings are commonly used in industrial settings today, and which factors should play a role in selecting the right protective coating?

At Redi, we’re here to offer a variety of industrial painting & coating services to clients around Colorado, Idaho, Nevada, Wyoming and nearby states in the Western US, in addition to our comprehensive industrial construction solutions. Here’s an industrial protective coatings guide: What they are and why they matter, their importance, and how to choose the ideal coating for any industrial equipment you utilize.

Industrial Protective Coating Basics and Importance

When we talk about industrial protective coatings, we are referring to a thin layer of material that is applied to surfaces in order to protect them from corrosion, wear and tear, chemical damage and more. These coatings can be made from a variety of materials such as paints, epoxies, polyurethanes, and enamels.

The importance of industrial protective coatings cannot be overstated. In industries such as oil and gas, manufacturing, transportation and more, equipment is constantly exposed to harsh environmental conditions such as extreme temperatures, chemicals and heavy machinery use. Without proper protection, these assets would deteriorate quickly leading to costly repairs or replacements.

Proper coating also plays a significant role in preventing accidents, ensuring worker safety and maintaining regulatory compliance. For example, coatings applied to pipelines can prevent corrosion and leaks, avoiding potential environmental disasters or harm to employees.

In addition to protection, industrial coatings also offer aesthetic improvements. They can provide a clean and professional appearance to equipment and facilities, which is especially important for customer-facing industries.

Types of Protective Coating for Industrial Equipment

Here are some of the most common types of protective coating used for industrial equipment today:

• Epoxy: Some of the most common industrial coatings are epoxy-based. These coatings are highly durable, resistant to chemicals and corrosion, and can withstand extreme temperatures. They are often used in the petrochemical, oil and gas, and marine industries.
• Polyurethane: This type of coating is known for its high abrasion resistance and flexibility. It is commonly used for heavy-duty equipment that experiences a lot of wear and tear.
• Polyaspartic: Similar to polyurethane, polyaspartic coatings offer superior abrasion resistance, but with a faster curing time. This makes them ideal for projects that require a quick turnaround.
• Ceramic: Ceramic coatings provide excellent chemical and corrosion resistance, making them a popular choice for the automotive and aerospace industries.
• Fluoropolymer: This type of coating is known for its non-stick properties and high resistance to chemicals, making it ideal for applications in the food and pharmaceutical industries.
• Zinc-rich primers: These coatings are made with a high concentration of zinc, which provides excellent corrosion protection. They are commonly used in marine and industrial environments.

Each type of coating has its own unique properties and benefits, but they all share the common goal of protecting the underlying substrate from damage. This is why choosing the right type of coating for your project is crucial.

Selection Factors

When it comes to choosing the ideal protective coating for industrial equipment, here are some key factors to keep in mind:

Operating Environment

One of the largest factors in choosing a protective coating is the environment in which it will be used. Different environments have varying levels of exposure to factors like moisture, chemicals, UV rays, and temperature fluctuations. For example, a coating that is suitable for use in a highly corrosive marine environment may not be effective for use in an industrial plant where there are high levels of chemical exposure.

Substrate Material

The material of the underlying substrate also plays a significant role in selecting the right type of coating. Some coatings adhere better to certain types of materials than others, so it’s important to consider whether your substrate is metal, concrete, or another material. The condition and preparation of the substrate will also impact how well the coating performs.

Exposure to Risks

Depending on the specific environment and industry, coatings may need to withstand a variety of risks such as corrosion, abrasion, chemical exposure, extreme temperatures, and UV radiation. Some coatings are specifically designed to protect against these risks while others may be more general purpose.

Surface Prep Factors

Another key factor in the success of a coating is proper surface preparation. This includes cleaning, degreasing, and removing any existing coatings or contaminants from the substrate. Failure to properly prepare the surface can lead to poor adhesion and ultimately result in coating failure.

In addition, the type of surface prep required will vary depending on the substrate material. For example, concrete surfaces may require acid etching while metal surfaces may need sandblasting. It’s important to carefully assess and follow the manufacturer’s recommendations for surface preparation before applying any coating.

Cost

Finally, you should consider both initial cost and full lifecycle cost when it comes to selecting the right protective coating for industrial equipment. If the initial cost of a coating is high, but it has a longer lifespan and requires less frequent reapplication, it may be more cost-effective in the long run. On the other hand, cheaper coatings that need to be reapplied often can end up costing more over time.

At Redi, we’re here to help with a wide range of industrial painting & coating services for clients around Wyoming, Nevada, Colorado, Idaho and nearby Western US states. Contact us today for more!