Top 5 Crucial Factors To Consider When Choosing Coatings For Lasting Protection
How To Choose The Best Coating System For Maximum Durability & Performance
When you choose a coating, you are not only fulfilling an aesthetic function in your infrastructure. You are also choosing what will be the protective barrier against corrosion, abrasion, chemical agents, or the environmental conditions of your organization. Whether your infrastructure is industrial, commercial, or energy-related, it is important to be able to choose accurately.
If you choose incorrectly, there may be a risk of premature failure, high maintenance costs, or even unnecessary operational downtime. This analysis is especially relevant in the southwestern United States, where the climate can expose many structures to high temperatures and increased risk.
To help you choose correctly, here are five factors to consider when selecting quality coatings.
1. Assessing Substrate Corrosion For Optimal Coating Effectiveness
First and foremost, it is always advisable to accurately assess the condition of the substrate. When active corrosion is present, it not only affects adhesion. The short-term performance of the system can also be completely compromised, even with high-end coatings.
It should be noted that corrosion is not a uniform phenomenon. In reality, there can be mild, widespread, or deep surface corrosion that penetrates the metal. Each requires a different treatment, including surface preparation.
Ignoring these differences can lead to premature failure. To avoid problems, we recommend doing the following:
During this stage, it is advisable to perform:
- Systematic visual inspections by area.
- Photographic records to document the actual condition of the asset.
- Identification of critical areas where corrosion is structural and not just superficial.
With this analysis, there are many important definitions. For example, it is understood whether an overcoat is sufficient or whether a much more aggressive removal is needed. Generally, through abrasive blasting.
In the case of industrial applications, it is also important to have a good pipeline corrosion protection product distributor. There, it is necessary to determine the compatibility between the substrate, environment, and coating. Choosing wisely, through a specialized company, can make all the difference when determining the useful life of the system.
2. Evaluating Coating Layers & Film Thickness For Increased Durability
Before applying any new system, you should know how many layers currently exist. You also need to know their actual thickness. At this point, you are probably thinking, “If I apply more coating, I will be better protected.” However, this is often a common mistake! In reality, excessive thickness can cause performance issues such as cracking or peeling.
Dry film thickness (DFT) directly influences the barrier capacity against corrosive agents. It also affects the adhesion between new and existing layers. For this reason, measurements should always be taken at multiple representative points. This allows you to obtain reliable data.
To do this properly, magnetic or induction gauges can be used, or even a cross-sectional inspection can be performed. This can be very helpful in identifying the accumulated thickness, but also the distribution of layers.
With this information, you will be able to answer some questions that may have arisen. For example, if you were unsure whether the existing system could safely receive a new coat. The same applies if you were wondering whether it was necessary to remove part of the previous coating or not. For this reason, this step is so important and should not be underestimated.
3. Testing Coating Adhesion For Strong & Reliable Protection
Do you want to determine if an overcoat will succeed? You should analyze the adhesion of the existing coating to the substrate. Even a system with adequate thickness can fail if the bond with the substrate is poor. After all, any weakness at that interface can compromise the performance of the coating.
To make a good diagnosis, it is essential to pay attention to the main warning signs. These include:
- Look for visible delamination between layers.
- Blistering is associated with moisture, soluble salts, or trapped contaminants.
- Cracks or fissures that indicate system fatigue or substrate movement.
If you want to correctly evaluate adhesion, it is recommended to use tests such as the cross-cut method or mechanical knife tests. These evaluations should always be done in areas where the dry film thickness was measured. Based on this, you can get an overview of the actual condition of the existing system.
Sometimes, it may be necessary to seek the help of a trusted industrial coating supplier or a specialist in the field. This way, you can ensure that the selected system will provide solid long-term protection. Remember that if adhesion is not efficient, applying a new coat over that base will only transfer the problem. That is why an expert opinion on the matter is so important!
4. Managing Cohesive Stress To Boost Coating Longevity
When a coating layer is added, the “cohesive stress” within the system increases. This is a phenomenon that occurs during curing. If it happens, it can cause cracks or detachment of the system. This is especially true if it is not designed to withstand that additional load.
It should be noted that rigid coatings, such as high-thickness epoxies, generate greater internal stresses than flexible systems. This shows that both the total thickness and the material’s nature should be evaluated.
If the structure is subject to thermal movements or vibrations, it is necessary to control cohesive stress to avoid failures in the medium term.
5. Factoring In Geographic Exposure For Weather-Resistant Coatings
Finally, you must consider the environment where the structure will operate. It is not advisable to ignore environmental conditions, as they are often a cause of premature failure. These factors often influence the system:
- UV radiation and prolonged sun exposure.
- Ambient humidity and condensation.
- Extreme temperature variations.
- Presence of industrial or atmospheric pollutants.
In areas with high solar radiation, it is essential to use coatings resistant to UV degradation. In cold climates or regions with freeze-thaw cycles, it is important that the coating be flexible. As you can see, it is a matter of understanding exactly where you are and what you need.
For example, working with a top-rated industrial coating supplier will allow you to choose solutions tailored to the area. This way, you minimize risks and ensure the integrity of the system.
Contact a Coating Professional To Ensure Long-Lasting Protection and Performance
To make the right choice, the best thing you can do is request a comprehensive technical assessment. This will take into account the substrate, the environment, and performance. The goal is to ensure long-lasting results to protect your entire infrastructure.
At B&W Distributors, Inc., we are proud of our experience in serving industry leaders. We can protect your infrastructure with customized solutions that will enable you to reduce long-term risks. Contact us today!
B&W DISTRIBUTORS INC.
Tel: (480) 924-8883
Email: info@bwdist.com
Web: https://www.bwdist.com/
ARIZONA
2702 N Ogden #107
Mesa, AZ 85215
