Protective coatings represent a small fraction of total asset CAPEX — yet they often dictate the majority of long-term maintenance costs.
At Corroshield Industrial Services, our aim is to support asset owners seeking to extend coating life, improve inspection outcomes, and reduce unplanned remediation. The following five strategies consistently deliver measurable savings across tanks, pipelines, and structural steelwork:
1️⃣ Optimise surface preparation standards
Up to 80% of coating failures originate from inadequate surface prep. Align preparation grades with the service environment and desired outcome — for example, ISO8501-1 Sa2½ / SSPC-SP10 may be required for immersion, splash or exposed zones, but ISO8501-1 St3 may be sufficient for low-exposure maintenance areas. Unnecessary over-preparation wastes time and money; under-preparation drives premature breakdown.
2️⃣ Select coating systems based on exposure classification (ISO 12944)
Avoid over-specification. A C5-M offshore system on a C3 internal frame adds unnecessary cost and complexity. Use design life vs. exposure mapping to determine the most suitable coating system (e.g. materials, DFTs, No. Of coats etc.)
3️⃣ Control environmental parameters during application
Ambient conditions — temperature, relative humidity, dew point differential — directly impact coating adhesion and cure. Continuous monitoring and recording prevent intercoat adhesion failures and costly rework.
4️⃣ Implement planned coating maintenance
Condition-based inspection and re-coating programmes significantly reduce full-strip and reapply costs. A 10–15% annual maintenance investment can extend full coating life by up to 200%.
5️⃣ Integrate inspection and QA documentation
Digital QA/QC systems (e.g. DFT readings, batch traceability, environmental logs) provide defensible evidence of compliance with manufacturer PDS and client specification. This reduces warranty disputes and improves predictability of lifecycle cost models.
🛡️ In short: precision in specification, preparation, and process control delivers the highest return on coating investment.
For support developing or implementing coating strategies across tank farms, energy assets, or industrial infrastructure, contact Corroshield Industrial Services!
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