The Importance of Surface Preparation Before Applying Industrial Coatings

Did you know why your industrial coating is failing, not just because of the coating itself but because of improper surface preparation? Studies show that nearly 80% of coating failures are linked to poor surface preparation. Whether it’s heat-reflective coatings for roofs, corrosion-resistant solutions for industries, or low-VOC coatings for sustainability, proper surface preparation can extend the lifespan of this functional coating.

What is Surface Preparation?

Simply put, surface preparation means adequately preparing the surface for a long-lasting and efficient coating. This involves removing pre-existing coatings, residues, surface defects, dust, organic debris, or other contaminants. 

Why is surface preparation so necessary? 

The effectiveness of an industrial coating largely depends on how well it adheres to the substrate. Proper surface preparation makes it easier for the surface to adhere to the coating. 

Impurities like dirt, rust, oil, or previous coatings might impede good bonding when present on the surface. This causes early coating failures such as peeling, blistering, and corrosion. Effective surface preparation overcomes challenges and guarantees that coatings protect vital industry infrastructure.

5 Points in more depth to see how surface preparation enhances coating performance

1. Surface Preparation Enhances Coating Adhesion

Roughening the surface can increase the area for the coating to grip. This enhances adhesion and reduces peeling or delamination over time.

2. Surface Preparation for Increased Durability

Industrial coatings, particularly energy-efficient coatings, protect important surfaces from wear and tear, thermal damage, and environmental damage. When surfaces are adequately prepared, coatings can better withstand the effects of harsh environments.

3. Surface Preparation to Prevent Coating Failure: 

When contaminants such as moisture, dirt, or oil are trapped under the coating, they form air or water pockets. This produces bubbling or scorching, resulting in the breakdown of industrial coating. This is less likely with proper surface preparation.

4. Surface Preparation Enhances Corrosion Resistance:

Industrial surfaces are frequently made of metal. Metal rusts easily, especially when it comes into contact with moisture or salt. Industrial coatings are commonly used to prevent corrosion. Moisture and salt, when present on the surface before coating, can interfere with the bonding process, leaving areas exposed. Surface preparation ensures a clean, dry surface for the coating to adhere to, reducing the risk of corrosion.

5. Surface Preparation Improves Aesthetics:

While aesthetics are not an important aspect of industrial coating, a clean and smooth surface produces a clean and uniform finish. This component is critical for coatings applied to building or home roofs and walls.

Key Steps in Surface Preparation

Different materials and applications require specific surface preparation methods, typically following set stages such as:

1. Cleaning the Surface

The first step in preparation is removing all visible contaminants. It is necessary to remove any previous coatings. 

Industrial surfaces often come in contact with oil, grease, chemicals and other pollutants. Any loose portions of the industrial surface should also be removed. Cleaning the surface makes the industrial surface ready for coating. 

2. Surface Profiling

Create a textured or roughened surface, increase the surface area and enhance the mechanical bond between the coating and the surface. Surface profiling may vary according to the time of the coating.

3. Moisture protection

Moist surface often delays the drying time of the coating. Moreover, industrial coatings perform the best when the industrial surface is dry. It is recommended to do moisture content testing on the surface (especially the concrete surface) before applying the coating. 

Surface Preparation for Different Types of Surfaces Before High-Temperature Coatings

High-performance heat transfer coatings are designed to protect various surfaces across multiple industries. The types of surfaces that typically require thorough preparation before coating include:

1. Metal Surfaces (Manufacturing, automotive and aerospace industries) 

• Degrease and clean with solvent cleaning to alkaline detergents
• Remove rust and oxide by abrasive blasting, mechanical grinding or chemical treatments
• Create a rough texture using abrasive blasting to improve coating adhesion
• Ensure no moisture is present before applying the industrial functional coating

2. Cement Surfaces(Construction, tanks, bridges or industrial buildings)

• Remove the weak top later using high-pressure water or detergent
• Use Acid, shot blasting or grinding to create rough surfaces
• Check moisture levels using a moisture meter to avoid coating failures

3. Plastic (Automotive parts and industrial equipment)

• Clean with isopropyl alcohol or detergent
• Create a rough surface with light sanding
• Chemical or Flame treatment for polymers such as polyethene or polypropylene 

Conclusion

It is important to remember that the right industrial coating alone does not guarantee optimal coating performance. Surface preparation is the basis of successful and long-lasting industrial coating. Neglecting this can lead to coating failures, increased maintenance costs, and reduced equipment lifespan.

What part of the surface preparation process do you find most important for your industry? Share your thoughts in the comments. 

If you are unsure about surface preparation before applying heat dissipation paint, high emissivity paint, heat insulation paint, or heat control roof paint, contact us for expert guidance. As a high-temperature coating manufacturer, we are ready to help you with your surface prep needs. Feel free to reach out to us at your earliest convenience.

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