Introduction
Maintenance coatings are a major line-item for asset and site owners — but spending more doesn’t always mean better protection. With smart planning, specification, and execution, you can extend coating life, reduce downtime, and maximise return on every pound spent. Below are practical, actionable recommendations to help you get more out of your maintenance coating budgets.
1. Begin with a Risk-Based Asset Prioritisation
– Inventory and classify assets by criticality, condition, and consequence of failure.
– Prioritise coating spend where failure would cause the biggest safety, environmental, or production impact.
– Use condition-based inspection data to target high-risk areas rather than blanket re-coating.
2. Invest in Better Surface Preparation
– Surface preparation quality is the most influential factor in coating life. Spend where prep matters: corrosion-prone joints, welds, and high-abrasion zones.
– Use the right standard (e.g. SSPC/NACE) and verify cleanliness with visual checks, blast profile measurement, and soluble salt testing.
– Consider coatings compatible with the level of preparation you can reliably achieve.
3. Specify Coatings Based on Whole-Life Cost, Not First Cost
– Compare coatings on lifecycle cost: expected service life, maintenance frequency, application complexity, and downtime cost.
– Favour formulations that reduce recoat frequency (epoxies with high dry film thickness, advanced polyurethanes, or new hybrid systems) even if the initial unit cost is higher.
– Include realistic environmental and exposure scenarios in manufacturer performance claims.
4. Optimise Coating System Selection by Zone
– Use a zoned approach: high-wear/high-corrosion areas get premium systems; low-risk areas get economical options.
– Apply specialised topcoats where UV and aesthetics matter, and robust barrier coats where corrosion control is primary.
– Match coatings to substrate and access constraints (e.g., confined spaces, submerged areas).
5. Build a Predictive & Planned Maintenance Program
– Move from reactive to predictive maintenance: schedule coating repair and touch-ups based on inspection data and failure modes.
– Implement a small annual budget for proactive touch-ups to avoid large-scale, costly re-coats later.
– Track trends in coating condition to forecast replacement cycles and smooth budget planning.
6. Standardise Specifications & Quality Control
– Create clear, concise specification templates with required prep, coating system, application conditions, and inspection criteria.
– Use factory-coated or prefabricated coatings where feasible to reduce on-site variables.
– Implement consistent QC: adhesion checks, dry film thickness (DFT) measurement, holiday testing, and thorough documentation.
7. Prioritise Contractor Value over Cost Effectiveness
– Invest in utilising highly skilled and experienced contractors to perform the surface preparation and coating works. This will reduce the chance of premature failure.
– Build long-term relationships with professional protective coating companies to benefit from them understanding your site requirements, systems and processes.
– Use contractors with robust quality management systems and inspection & test procedures to ensure any works are delivered to specification and there is a clear record of any inspection and test results undertaken.
8. Improve Project Planning & Logistics
– Plan coating work around optimal weather conditions and production schedules to reduce failed applications, downtime and rework.
– Ensure proper storage, mixing, and handling of materials on site. Shortcuts here degrade performance quickly.
– Coordinate scaffolding, access, and surface prep so work flows efficiently and downtime is minimised.
9. Leverage Technology & Monitoring
– Use non-destructive testing (NDT) tools, digital inspection platforms, and mobile apps to record conditions and repairs in real time.
– Consider corrosion sensors or probes in critical locations to quantify deterioration and validate coating performance.
– Use data to refine specifications, procurement, and budgeting.
10. Negotiate Value-Based Contracts
– Move away from lowest-bid procurement. Use best-value selection criteria incorporating lifecycle cost, warranty terms, past performance, and technical capability.
– Include performance incentives and warranties tied to measurable outcomes (e.g., adhesion, blistering, rust-through timelines).
– Consider long-term service agreements with scheduled touch-ups and condition monitoring.
11. Use Pilot Projects to Validate New Products
– Trial new coatings or application methods on a small, representative area before full-scale rollout.
– Monitor performance and costs, and adjust specs or processes based on real-world results.
– Pilot data reduces risk and helps justify higher upfront investment where justified.
12. Reclaim Value from Remaining Coatings
– When full replacement isn’t necessary, apply effective remediation strategies: spot repairs, localised coating over compatible systems, or surface renewers that extend service life without full strip-and-recoat.
– Ensure compatibility testing (e.g., adhesion, solvent rub tests) before overcoating to avoid premature failures.
13. Value Innovative Approaches
– Use drone and robotic technology to perform inspections and work where access is restricted to minimise scaffold costs.
– Use drone and robotic technology to perform inspections and work in confined spaces where possible to remove the need for confined space entry and standby rescue teams.
– Consider powered access or rope access as an alternative to scaffolding.
Conclusion — Make Budgeting Strategic, Not Reactive
Getting more from your maintenance coating budget means shifting to strategic, data-driven decisions: prioritise assets, invest in preparation and skilled application, choose coatings for whole-life value, and implement consistent inspections and QC. Small, well-targeted investments today (better prep, training, and monitoring) often produce the largest reductions in long-term costs and downtime.
Our experienced team at Corroshield Industrial Services can assist you in implementing the above strategies to help you achieve better value from your ongoing maintenance budgets. Don’t hesitate in contacting us on 01200 411 768 or info@corroshield.co.uk and we would be happy to help.