As a leading industrial coatings company, our team at Sun Coating Company understands how frustrating it can be when coatings fail prematurely. Our goal is always to provide coatings that stand the test of time in even the harshest industrial environments. However, despite any company’s best efforts, coatings can still fail sometimes. Here are some of the most common reasons coatings fail and provide tips to help prevent failures.
Surface Preparation Issues
One of the most common reasons industrial coatings fail is inadequate surface preparation. Coatings require a clean, contaminant-free surface to properly adhere. Any dirt, oil, grease, rust, or other contaminants can cause coatings to lose adhesion. Even unseen contaminants like vapor residues can lead to coating failure down the road.
Thoroughly clean and degrease surfaces before coating application. On metals, remove any rust and create the proper surface profile for mechanical bonding. Inadequate surface prep accounts for over 60% of industrial coating failures. Don’t cut corners here.
Incompatible Materials
Coatings are formulated for specific materials like steel, aluminum, and plastic. When a coating isn’t compatible with the substrate, the result is usually premature failure. Using a coating meant for steel on aluminum will likely lead to delamination or blistering.
Always verify coating compatibility and use coatings formulated for your specific substrate. At Sun Coating Company, we can recommend compatible coatings for virtually any substrate. Our coatings, like polyurethane foam mold coatings, are engineered for common industrial materials.
Incorrect Film Thickness
Applying coatings at the wrong film thickness is a very common mistake. Coatings applied too thin won’t provide adequate protection and durability. Overly thick coatings will experience sagging, cracking, or imprinting.
Follow the product data sheet for proper film thickness and confirm thickness with wet film gauges during application. Too thick or thin by more than 10% often leads to failure. Proper film thickness ensures optimal performance.
Curing Issues
Coatings require time and the proper conditions to fully cure. When coatings don’t fully cure, performance will be severely impacted. Coatings may never reach full hardness or chemical resistance.
Allow adequate time for coatings to cure based on product data sheets. Ensure the required temperature and humidity levels for curing are met. Forced curing can be used to accelerate cure times when necessary. Uncured or partially cured coatings will almost always lead to premature failure.
Exposure Before Curing
Exposing coatings to chemicals, abrasion, or other factors before fully curing is another common mistake. Coatings in the curing process are vulnerable. Any exposure can permanently damage the coating, quickly leading to failure once put into service.
Isolate freshly applied coatings from all chemicals, abrasion, fluids, and other factors until completely cured. Avoid touching, walking o,n or otherwise disturbing curing coatings. Patience during the curing process will pay off.
Off-Ratio Mixing
Two-component coatings require mixing resin and catalyst at the proper ratio. When off-ratio mixing occurs, coatings will not cure correctly. They’ll remain tacky and soft, rapidly failing once put into service.
Carefully follow mix ratios and measure components precisely. Calibrate spray equipment regularly to ensure proper metering. Confirm ratios with periodic scrape tests. Off-ratio coatings must be fully removed and reapplied correctly.
Poor Surface Profile
An adequate surface profile provides the mechanical bonding that coatings require for abrasion and impact resistance. Surfaces that are too smooth prevent mechanical bonding, limiting coating adhesion. This is especially important for a dry film lubricant coating.
Achieve the recommended anchor profile for each coating, typically 2+ mils. Blasting, power tools, and chemical etching all create a proper profile. Slick surfaces like stainless steel may require abrasive blasting. The profile should appear uniform and jagged under inspection.
Do You Need an Industrial Coating? Call Us
When an industrial coating fails prematurely, one or more of these factors are usually the root cause. Following the tips provided will help avoid failures and maximize the coating lifespan. Of course, choosing a reputable coatings company like Sun Coating Company is also key. Our experts can recommend the ideal coating system for your specific application challenges. Reach out to us to get started improving your industrial coating performance. We look forward to partnering with you.