Maximising Corrosion Protection with Specialist Coatings

Surfaces are constantly exposed to environmental factors that can lead to corrosion, wear, and damage. Whether it’s industrial equipment, steel structures, pipework or bulk liquid storage tanks, ensuring durability through effective coating is essential. In this guide, we’ll explore how you can maximise corrosion protection with proven coating techniques, helping you extend the lifespan of materials and reduce maintenance costs.

What Is Surface Coating and Why Is It Important?

Protective coating involves applying a barrier layer to a material to shield it from environmental factors like moisture, UV rays, and chemical exposure. This process not only prevents corrosion but also enhances the aesthetic appeal and functionality of the asset.

Coating serves as a barrier, creating a shield against potential damage. For example, in industrial settings, structures or tanks coated with anti-corrosion materials lasts significantly longer than untreated assets. This results in cost savings and minimised downtime.

What Are the Common Types of Protective Coatings?

Choosing the right coating is critical for achieving optimal protection. Here are some common types of surface coatings:

1. Epoxy Coatings: Known for their extreme durability and versatility, epoxy coatings are ideal for industrial and marine applications. They create a hard, durable surface that withstands heavy wear. Solvent free epoxies are widely used in industrial applications for their low VOC content and environmentally friendly properties.
2. Vinyl Ester Coatings: Vinyl esters make excellent lining materials for storage equipment such as bulk liquid storage tanks that contain aggressive acids. 
3. Polyurethane Coatings: These coatings are flexible yet tough, they offer UV-protection and provide a smooth gloss finish which simplifies cleaning and maintenance.
4. GRP Coatings: Particularly useful when lining storage tanks and bunds, GRP coatings where an epoxy or polyester based resin is reinforced with chopped strand mat for an extremely durable finish.
5. Metallic Coatings: These involve applying a thin layer of metal, such as zinc or aluminum, to protect against rust and corrosion.
6. Thermal Insulation Coatings: This type of coating system is a fantastic alternative to traditional insulation and lagging systems used to minimise heat loss. Thermal insulation coatings remove the risk of corrosion under insulation (CUI) whilst also providing superior safety and thermal efficiency benefits.
7. Intumescent Coatings: Coatings designed to intumescent when heat is applied to maintain the integrity of steel under extreme temperatures. Often known as passive fire protection, this can be used in commercial or general construction applications (cellulosic) or industrial applications where there is a risk of jet or pool fires (hydrocarbon).

How to Choose the Right Protective Coating for Your Needs

Selecting the appropriate protective coating depends on several factors, including the material, environmental conditions, and intended use. Here’s a step-by-step approach:

1. Assess the Environment: Identify whether the surface will be exposed to moisture, chemicals, or high temperatures.
2. Determine the Material: Check if the base material is metal, wood, plastic, or concrete, as each requires specific coatings.
3. Assess Site Specific Requirements: Are there access challenges to overcome? Is the site hazardous? Is confined space working or working at height required? Does the work require encapsulation to prevent impacting other works/personnel/neighbours? etc. 
4. Evaluate Task Objectives: What does the coating need to achieve (anti-corrosion? Weather resistant? Fire protection? Chemical resistant? Abrasion resistant?) Does the customer want a cost effective, short term solution? Is the scope part of a larger maintenance project where extensive durability and service life are required? What aesthetic properties does the coating need to have on completion?
5. Evaluate Durability Needs: For high-traffic areas or industrial equipment exposed to aggressive environments, prioritise coatings known for their strength and longevity.
6. Consult Experts: Hiring a professional coatings company will ensure the project meets the goals of the asset owner, whilst maintaining high levels of safety, sustainability and quality throughout the project. 

What Are the Steps in the Protective Coating Process?

While the exact steps vary depending on the coating type, the general process includes:

1. Surface Preparation: Cleaning the surface to remove dirt, oil, old paint and loose rust. Grit blasting or tool preparing the surface in line with the project specification to ensure optimal adhesion is achieved.
2. Application: Using brushes, sprays, or rollers to apply the coating evenly in line with the paint manufacturer’s application guidelines.
3. Curing: Allowing the coating to dry and harden, often under specific temperature and humidity conditions.
4. Inspection: Checking for uniformity and ensuring there are no holidays, defects or imperfections that could cause the system to fail prematurely.

Top Benefits of Protective Coatings

Applying a protective coating comes with numerous advantages:

•  Longevity: Coated surfaces last significantly longer, reducing the need for frequent replacements.
•  Cost Savings: Minimised maintenance and repair expenses.
•  Enhanced Appearance: Coatings improve the visual appeal of materials, making them look new and polished.
•  Environmental Protection: Specialised coatings can protect surfaces from harmful UV rays and pollutants.
•  Safety: Anti-slip coatings enhance safety in workplaces and public areas. Corrosion protection can prevent loss of containment for storage tanks and pipework risking safety catastrophes.

What Are the Challenges in Protective Coating?

Despite its benefits, surface coating can be challenging without proper knowledge or tools. Common issues include:

•  Adhesion Problems: Poor surface preparation can lead to peeling and flaking.
•  Inconsistent Application: Uneven coatings result in weak spots vulnerable to wear and tear.
•  Environmental Impact: Some coating materials release volatile organic compounds (VOCs). Opting for eco-friendly options mitigates this concern.

How to Maintain Coated Surfaces

Once a surface is coated, proper maintenance ensures its longevity. Here are some tips:

•  Regular Cleaning: Use mild detergents and soft cloths to clean coated surfaces without damaging the protective layer.
•  Avoid Harsh Chemicals: Certain cleaners can degrade the coating over time.
•  Inspect Periodically: Look for signs of wear, peeling, or cracking and address them promptly.

FAQ: Common Questions About Surface Coatings

1. How long does a surface coating last?
The lifespan depends on the type of coating and environmental conditions but typically ranges from 5 to 25 years.

2. Can surface coatings be applied to any material?
Most materials, including metal, wood, and plastic, can be coated. However, the preparation and type of coating vary.

3. Are surface coatings eco-friendly?
Many modern coatings are environmentally friendly, offering low-VOC or water-based options.

4. What’s the cost of professional coating services?
Costs vary based on material, surface size, and type of coating. Getting a personalised quote is recommended.

5. How can I remove an old or damaged coating?
Sanding, chemical strippers, high pressure water jetting and abrasive blasting are common methods for removing old coatings.

Maximising surface durability through effective coating techniques is a worthwhile investment for both individuals and industries. By understanding the types, benefits, and maintenance of coatings, you can extend the life of your materials and enjoy long-term savings. For companies who engage in asset integrity and maintenance to ensure the sustainability and safety of their operations, seeking professional expertise guarantees that your surfaces are properly protected against environmental challenges.