How To Apply Industrial Coatings: Step-By-Step Application Process with Cumulus Pro

Industrial coatings play a vital role in protecting the surfaces of our most critical infrastructure from corrosion, wear and tear, and environmental damage. Whether it's an offshore oil platform or a manufacturing facility, applying industrial coatings correctly ensures the longevity and durability of components.  

In this comprehensive guide, we'll delve into the intricacies of industrial coatings, explore different types and techniques, highlight common mistakes, and provide a step-by-step process for application. 

To walk you through the entire industrial coatings process in as much detail as possible, we’ll be using welding inspection workflow on the Cumulus Pro app. If you’re interested in trying it out for your next industrial coatings job, you can take advantage of a 30 day free trial by downloading it from the App Store or Google Play. 

What are Industrial Coatings? 

Industrial coatings are specially formulated paints or coatings designed for application on various surfaces in industrial settings. Unlike conventional paints, industrial coatings offer enhanced protection against harsh environmental conditions, chemicals, and abrasion.  

They serve as a barrier between the substrate and external elements, preventing corrosion, rust, and deterioration. Additionally, industrial coatings can provide aesthetic appeal, improve safety by adding non-slip properties, and meet regulatory requirements such as fire resistance or chemical containment. 

Different Types of Industrial Coatings 

Industrial coatings come in various formulations, each tailored to specific applications and substrates. Some common types include: 

• Epoxy Coatings: Known for their excellent adhesion and chemical resistance, epoxy coatings are ideal for concrete floors, metal surfaces, and industrial equipment. 
• Polyurethane Coatings: Polyurethane coatings offer exceptional durability, UV resistance, and flexibility, making them suitable for outdoor applications, such as bridges, pipelines, and marine structures. 
• Polyurea Coatings: These fast-curing coatings provide superior abrasion resistance and are often used for waterproofing, containment, and secondary containment in industrial settings. 
• Acrylic Coatings: Acrylic coatings are valued for their weather resistance, color retention, and ease of application. They find use in architectural coatings, automotive components, and machinery. 
• Zinc-rich Coatings: Primarily used for corrosion protection, zinc-rich coatings create a sacrificial barrier that prevents rust formation on steel structures, pipelines, and marine equipment. 

Different Industrial Coating Techniques 

Industrial coatings can be applied using various techniques, depending on the substrate, coating type, and desired finish. Some common methods include: 

• Spray Application: Ideal for large surface areas, spray application ensures uniform coverage and fast drying times. It's commonly used for applying epoxy, polyurethane, and polyurea coatings on floors, walls, and structural steel. 

• Roller Application: Roller application is suitable for surfaces with irregularities or vertical structures where spray application may be challenging. It provides good coverage and is often used for applying epoxy coatings on walls and ceilings. 
• Brush Application: Brush application allows for precise control over coating thickness and is commonly used for touch-up work, small areas, or detailed applications where spray or roller methods are impractical. 
• Dip Coating: In dip coating, the substrate is immersed in a tank of liquid coating material, ensuring complete coverage. It's commonly used for coating small, complex-shaped parts or components such as fasteners, springs, and automotive parts. 

Common Mistakes Made when Applying Industrial Coatings 

Despite the importance of proper application, several common mistakes can compromise the effectiveness and longevity of industrial coatings: 

• Inadequate Surface Preparation: Failing to properly clean, degrease, or roughen the substrate surface can lead to poor adhesion and coating failure. 
• Incorrect Mixing Ratios: Many industrial coatings require precise mixing ratios of base and hardener components. Deviating from these ratios can result in improper curing and reduced coating performance. 
• Insufficient Drying or Curing Time: Rushing the drying or curing process can lead to premature failure of the coating. It's essential to follow manufacturer recommendations for drying and curing times before subjecting the coated surface to use or exposure. 
• Poor Ventilation: Applying coatings in poorly ventilated areas can result in solvent entrapment, bubbles, or uneven drying, affecting the appearance and performance of the coating. 
• Ignoring Environmental Conditions: Extreme temperatures, high humidity, and airborne contaminants can adversely affect coating application and curing. It's crucial to work within specified environmental conditions to ensure optimal results. 

How To Prepare for the Industrial Coating Process 

Proper preparation is key to a successful industrial coating application. Follow these steps to prepare for the coating process: 

• Assess Surface Condition: Inspect the substrate for any damage, corrosion, or surface contaminants. Repair any defects and ensure the surface is clean and dry. 
• Select the Right Coating: Choose an industrial coating that is compatible with the substrate material, environmental conditions, and performance requirements. 
• Gather Necessary Equipment: Depending on the chosen coating method, gather the required equipment, including spray guns, rollers, brushes, mixing tools, and personal protective equipment (PPE) such as respirators, gloves, and safety goggles. 
• Prepare the Work Area: Clear the work area of any obstacles, debris, or equipment that may interfere with the coating process. Ensure adequate ventilation and lighting for safe and efficient work. 
• Follow Manufacturer Guidelines: Read and understand the manufacturer's instructions, including surface preparation recommendations, mixing ratios, application techniques, and safety precautions. 

Step-by-Step Process for Applying an Industrial Coating 

Now, let's outline a step-by-step process for applying an industrial coating using Cumulus Pro. If you’d like to follow along with a 30 day free trial, download it from the App Store or Google Play. 

Step 1: Surface Preparation 

Thoroughly clean the substrate surface using a degreaser or suitable solvent to remove dirt, oil, grease, and other contaminants. To do this, it’s important to use a bristle blaster or other tool to prepare the surface to receive coatings. 

For concrete surfaces, consider mechanical methods such as shot blasting or grinding to achieve the desired surface profile. 

Step 2: Masking and Protection 

Mask off any areas that are not intended to be coated, such as adjacent surfaces, fixtures, or equipment. Use painter's tape and plastic sheeting to protect surrounding areas from overspray or drips. 

Step 3: Mixing 

Carefully measure and mix the industrial coating components according to the manufacturer's instructions. Use a clean mixing container and stir thoroughly to ensure uniform consistency. 

Step 4: Application

Depending on the chosen application method, apply the industrial coating evenly to the prepared surface. Maintain the recommended wet film thickness (WFT) and avoid excessive build-up or thin spots. Work systematically to ensure complete coverage without missing any areas. 

Step 5: Inspection 

Inspect the coated surface for any defects, such as bubbles, runs, or uneven coverage. Address any issues immediately by smoothing out bubbles or removing excess coating before it dries. 

Step 6: Curing 

Allow the applied coating to dry or cure according to the manufacturer's specifications. Ensure proper ventilation and temperature control to facilitate the curing process and achieve optimal coating performance. 

Step 7: Quality Assurance 

Once the coating has cured, conduct a final inspection to ensure that it meets the desired quality standards. Check for adhesion, appearance, and overall performance to confirm successful application. 

Step 8: Clean-Up 

Clean tools, equipment, and work area promptly using appropriate solvents or cleaning agents. Dispose of any leftover coating materials or waste according to local regulations. 

Conclusion 

By following these steps and utilizing Cumulus Pro, you can achieve professional-quality results in industrial coating applications, ensuring maximum protection and durability for your surfaces.