Industrial coatings play a critical role in protecting metal surfaces from corrosion, wear, and harsh environmental conditions. However, even the most-expensive, highest-performing coatings can fail prematurely if not applied correctly. In this article, we’ll highlight some of the most common coating mistakes and how to avoid them to ensure optimal performance and durability.
1. Inadequate Surface Preparation
One of the most significant causes of coating failure is poor surface preparation. Coatings need a clean, properly profiled surface to adhere effectively. Skipping this step can lead to adhesion issues, premature peeling, or corrosion underneath the coating.
How to Avoid It:
- Remove all contaminants such as oil, grease, and dirt using appropriate cleaning methods.
- Use abrasive blasting, grinding, or chemical treatments to create the right surface profile for adhesion.
- Ensure surfaces are completely dry before applying any coating.
2. Applying Coating Over Moist or Contaminated Surfaces
Moisture, dust, or other contaminants trapped under a coating can lead to poor adhesion and coating defects such as bubbling or blistering.
How to Avoid It:
- Always inspect and test the surface for moisture before application.
- Use proper ventilation to eliminate excess humidity.
- Wipe down surfaces with clean, dry cloths and use air blowers if necessary.
- Check the weather forecast to avoid rain, dew, and extremely high humidity.
3. Incorrect Mixing and Application Techniques
Improperly mixed coatings or incorrect application methods can lead to uneven coverage, poor film formation, and reduced durability.
How to Avoid It:
- Follow the manufacturer’s instructions on mixing ratios and induction times.
- Use the recommended application tools (sprayers, rollers, or brushes) to ensure even coverage.
- Stir coatings thoroughly to prevent pigment settling and maintain consistency.
4. Applying Coatings Too Thick or Too Thin
Applying coatings too thick can result in cracking, extended drying times, or improper curing. Conversely, applying too thin of a layer can lead to inadequate protection and reduced lifespan.
How to Avoid It:
- Use a wet film thickness gauge to ensure the correct application thickness. You may even re-test dry film as an added measure.
- Apply multiple thin coats instead of a single thick one if needed.
- Allow adequate drying time between coats.
5. Ignoring Recoat Windows
Recoat windows are critical for proper bonding between layers. Applying a second coat too soon or too late can result in delamination and poor adhesion.
How to Avoid It:
- Always check the manufacturer’s recommended recoat time.
- If the recoat window is missed, lightly sand the surface before applying the next layer.
6. Improper Storage and Handling
Storing coatings in extreme temperatures or failing to seal containers properly can cause degradation, leading to poor application results.
How to Avoid It:
- Store coatings in a controlled environment, away from direct sunlight and extreme temperatures.
- Always reseal containers tightly to prevent contamination and drying out.
- Check expiration dates before use.
7. Using the Wrong Coating for the Job
Not all coatings are suited for every environment. Using the wrong type can lead to premature failure and costly repaints.
How to Avoid It:
- Consult with coating specialists to select the right product for your specific application.
- Consider environmental factors like temperature, humidity, and exposure to chemicals.
- Ensure compatibility with primers and other coatings in the system.
Conclusion
Avoiding these common coating mistakes will significantly extend the life of your coatings and improve their performance. The basic guidelines include: Proper surface preparation, correct application techniques, and adherence to manufacturer guidelines are key to achieving durable, high-quality finishes. By following these best practices, you can reduce costly failures and maintain the integrity of your coated surfaces, and protect your investment.
Need expert advice on selecting and applying the right coating for your project? Contact us today to learn more about our industrial coatings and how they can benefit your business.
