Expensive machinery and flooring deserves to be protected. Protective coatings provide a durable barrier to shield your investments from damage and corrosion. Using high-performance coatings in an industrial setting helps you increase the lifespan of your assets and avoid costly repairs or replacements.
What are Industrial Coatings?
Industrial coatings are a specialized type of paint that’s used to protect, enhance, and prolong the life of surfaces and structures in an industrial setting. Unlike regular paint, high-performance protective coatings are formulated to extend the lifespan of equipment and structures in a corrosive environment.
Why are Industrial Coatings Important?
High-performance industrial coatings are a necessity in harsh industrial environments. High temperatures, abrasive chemicals, persistent humidity, and exposure to the elements can break down and erode machinery, steel, and concrete. Applying industrial coatings to your company’s assets can extend their lifespan and save your business money on repairs. Coatings can also improve the efficiency of machinery by reducing friction along with enhancing safety by preventing the spread of fire.
Benefits of Industrial Coatings
Applying industrial coatings can provide several different benefits:
Protection
The primary benefit of coatings is protection. Coatings protect machinery and structures from corrosion, abrasion, and environmental factors. Simply applying a transparent coating can help surfaces last for years.
Efficiency
Industrial coatings can be applied to reduce friction in machinery, speeding up production and increasing factory efficiency. The faster a machine can run without needing to be repaired increases your productivity.
Durability
A protective coating on machinery extends the lifespan of the parts, saving you money on repair or replacement. Having machinery that works longer without needs for repair saves you money.
Appearance
In addition to their protective benefits, industrial coatings can also improve the aesthetic appearance, adding color, and creating a smooth shiny appearance when applied. A newly-painted surface or machinery creates a great impression for employees or visitors.
Improved Safety
Industrial coatings can increase workplace safety. Slip-resistant coatings can be applied to floors to prevent employees from slipping and falling down. Heat-resistant coatings can be applied to extremely hot equipment which reduces heat transfer in the event that an employee touches the hot machinery. Tumescent paint can be used to slow and reduce spread in the event of a fire.
Surface Protection
Industrial coatings can be applied to concrete floors and metal work surfaces for added protection. Epoxy is often added to flooring to prevent wear and scuffing from foot traffic and small vehicles like forklifts. Untreated concrete in an industrial setting is prone to damage from vehicles and harsh chemicals. Coatings protect these high-traffic surfaces to improve their longevity.
Fire Prevention
Some types of industrial coatings can actually prevent fires from spreading. Intumescent paint is a specially-formulated coating that when exposed to fire will expand and char without catching on fire. When the paint heats up, it begins to bubble, creating a protective gap between the fire and the underlying surface. This gap of air keeps the surface underneath from burning or melting, helping to maintain the building’s structural integrity for up to 120 minutes.
Corrosion Prevention
Industrial workspaces contain lots of corrosive elements including humidity, high temperatures, and harsh chemicals. Without proper treatment any nearby metal objects like machinery and equipment will become rusted and corroded over time. Applying industrial coatings to metal will protect it from corrosive damage.
Durability and Longevity
Industrial coatings protect surfaces and equipment to increase their durability and their longevity. A hard and durable finish protects surfaces from wear and tear caused by heavy foot traffic, abrasion, environmental conditions, and harsh chemicals. By negating common types of damage and corrosion, industrial coatings reduce the need for maintenance and repair.
Lower Maintenance Costs
Thanks to the increased durability, industrial coatings help business owners save money. Because they avoid damage, surfaces and equipment that are painted with industrial coatings result in lower maintenance costs over time. A one-time application of a protective coating can keep equipment operable, saving money on replacement parts or repairs.
Environmental Protection
The formulation of industrial coatings can help protect the environment. Because coatings increase the lifespan of materials and equipment, it results in less material waste or need for replacement. Coatings can also contain low volatile organic compounds (VOCs) which helps reduce air pollution.
Equipment Improvement
Industrial coatings can be applied to your existing equipment to improve performance. Coatings that reduce friction can be applied to moving parts to increase the machine’s efficiency. Industrial coatings can also include additives that prevent the growth of bacteria, which is important in medical industries or food production.
Regulatory Compliance
Industrial coatings are a simple way to ensure that a business is in compliance with regulations. Because coatings need to be formulated with low to no volatile organic compounds (VOCs) they help businesses comply with environmental and health standards. Coatings can help businesses stay compliant with regulations and avoid fines or legal problems.
Decreases Downtime
When important machinery becomes damaged, work screeches to a halt. Because industrial coatings protect machinery parts from corrosion and damage, it means they’ll last longer in harsh environments, reducing unwanted downtime for repair. An investment in industrial coatings results in reduced downtime, and more profitability for the business.
Easier Cleaning
When adding industrial coatings to flooring and walls, you create a smooth, non-porous surface that’s easier to clean. Without cracks and crevices in the floor, there’s no place for dirt and grime to collect. This makes for a more sanitary working environment that can be easily cleaned.
Improved Aesthetics
In addition to all of the important benefits of industrial coatings they also spruce up a facility by providing a fresh coat of paint. It won’t be obvious to the naked eye, but that shiny coat of paint is also protecting your business and providing an attractive workspace for employees.
Types of Industrial Coatings
There are various types of industrial coatings that each have their own specific uses. Here’s an overview of each type of coating along with their pros and cons.
Polyurethane Coatings
What are PU coatings? Polyurethane coatings (also known as “PU” coatings) are a popular type of industrial coating that’s known for its durability and high-gloss finish. It’s easy to clean and provides a thick, moisture-resistant seal after curing. Polyurethane coatings are used in a number of different industries that include: aerospace, automotive, and construction.
Pros
- Quick curing times, under 24 hours
- Strong resistance to high temperatures
Cons
- When burned it emits toxic fumes
- More expensive than similar types of coatings
Acrylic Coatings
Acrylic coatings are a popular type of industrial coating. It’s used as a barrier against moisture and humidity, as well as protecting surfaces from mold and fungus. Acrylic coatings can be used to protect concrete and steel, as well as electronics due to the fact that it’s non-conductive.
Pros
- Corrosion resistant
- Excellent durability
Cons
- Can lose thickness due to weathering
- Needs to be applied at high temperatures
Epoxy Coatings
Epoxy coatings are a common protective coating made by combining epoxy and a hardening agent. When combined, the epoxy begins curing and a few hours later is completely solid. Epoxy is transparent and durable, making it a popular coating for floors and other surfaces.
Pros
- Provides an attractive and durable finish
- Can last for up to twenty years
Cons
- Can become yellowed after frequent exposure to sunlight
- Without anti-slip additives, epoxy may be slippery when wet
Zinc-Rich Coatings
As its name implies, zinc-rich coatings contain a high level of zinc dust. They’re applied to steel surfaces to prevent galvanic corrosion. Instead of the steel becoming corroded, the coating sacrifices itself to corrosion. Zinc-rich coatings are commonly used to protect steel, so they’re used on highways, infrastructure, and in industrial settings.
Pros
- Less expensive than other coatings
- Superior corrosion prevention for steel and iron
Cons
- Requires thorough surface preparation before application
- The zinc is consumed to prevent corrosion, meaning it will need to be re-applied periodically
Ceramic Coatings
Ceramic coatings are used to increase durability and performance to machine parts and surfaces in an industrial setting. The ceramic coating reduces wear and tear and increases the lifespan of the coated object. Ceramic coatings are often used in industries like aerospace, textiles, and food processing.
Pros
- High abrasion resistance
- Tolerates extreme heat
Cons
- More expensive than other types of coatings
- Requires periodic maintenance and upkeep
Intumescent Coatings
Intumescent coatings are specially-formulated to be flame resistant and slow the spread of fire. When exposed to high temperatures, they swell and expand to create a pocket between the fire and the object beneath the coating. The intumescent paint will scorch – but not catch fire – preventing the fire’s spread.
Pros
- Provides passive fire protection
- Also prevents corrosion
Cons
- Can cost several dollars per square foot
- May also require surface preparation and topcoat
Anti-Slip Coatings
Anti-slip coatings are sprayed on floors to make them grip better, reducing the risk of slipping and falling. This textured coating improves traction even in wet conditions. Anti-slip coating can be applied to most floor surfaces, including vinyl flooring, tile, and polished concrete.
Pros
- Increases employee safety
- Easy to clean and maintain
Cons
- Can wear off and become less effective over time
- Not compatible with some types of flooring
Antimicrobial Coatings
Antimicrobial coatings are commonly used in a healthcare setting like hospitals or clinics. Disease-carrying droplets and particles can collect on surfaces spreading disease. Antimicrobial coatings used to sterilize surfaces, preventing the collection and growth of harmful microbes. These coatings contain chemicals that stop the growth of viruses, bacteria, mold, and fungi.
Pros
- Reduces the spread of disease
- Durable, long-lasting protection
Cons
- Ingredients like metal ions could harm human cells
- May not be effective against some types of microbes
Contact Us for Industrial Coatings in Philadelphia
Now that you’re familiar with all of the ways that industrial coatings can extend the lifespan of your assets, contact the professionals at Alpine Painting & Restoration. We’ll walk you through all of the coatings options that can best suit your needs, and provide you with a free quote. We’ve been proudly serving Philadelphia-area businesses for more than three decades, and we can help your company save money with durable industrial coatings
