How To Choose The Right Metal Industrial Coatings

When it comes to industrial coatings, making the right choice can be a daunting task. Yet each method has its own unique advantages and function. Some options may not be right for you. While there are many different types of industrial coatings to choose from, understanding the costs, savings, benefits, and liabilities associated with each technique is vital in making the right choice.

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While some industrial coatings work well across the board, others are ideal for specialized applications. Start-up costs, maintenance, and the cost of operation should also be taken into consideration to ensure the right choice.

This guide will compare and contrast the many industrial coatings options available to you. Knowing what each option offers will enable you to choose the optimal solution for your unique coatings needs.

Industrial Coatings

There are many different types of industrial coatings, but essentially, the term refers to any coating – typically paint – used to protect manufactured products from corrosive elements, fire, chemicals, etc. Industrial coatings are the second largest coatings market in the US, worth approximately $7.8 billion USD as of .

Coatings protect and beautify and therefore enhance the value of many items. And the value-added far exceeds the cost of the coating process and materials. Industrial coatings are made from a wide variety of materials, such as alcohols, biobased feedstocks, iron oxide, aluminum pigments, epoxies, polyesters, and even gold.

The Need for Metal Finishing

Metal Finishing has come to refer to protecting both metal and non-metal surfaces, but it has typically referred to the process of applying a finishing coat to protect metal products. It can include both paint and non-paint coatings solutions.

Metals are highly susceptible to rust wherever both oxygen and moisture are present. Pollutants like salts or sulphur dioxide only expedite this degenerative process. Additionally, metal vehicles used by the US military rely on state-of-the-art Chemical Agent Resistant Coatings (CARC) to protect surfaces from chemical and biological warfare agents. Some of the primary reasons for metal finishing include:

• Increased surface thickness
• Aesthetic improvements
• Corrosion resistance
• Increased strength
• Increased adhesion
• Durability
• Improved electrical conductivity
• Chemical resistance
• Enhanced solderability
• Enhanced electrical conductivity

While modern paints have developed greater protective properties than their predecessors, this superior protection is dependent on optimal coating selection, site preparation, and proper application. Undercoats and primers are necessary for some industrial coatings but not others. Baking and heat curing benefit some metal coatings but can damage others. Choosing the proper protective metal coating and metal finishing technique is paramount – and it doesn’t have to be all that difficult.

Popular Industrial Coatings Methods

There are numerous methods of protecting industrial surfaces currently in use today. Some methods are vastly different than others, while some have subtle pros and cons that should be carefully considered depending on the situation. While most people think of paint when discussing coatings, there are other metal finishing options used in very limited circumstances. In general, the metal coating methods commonly used today include:

• Anodizing
  Most common with aluminum, this method increases the thickness of aluminum oxide that occurs when aluminum is exposed to oxygen. This process makes aluminum (and some other metal surfaces) more resistant to corrosion and can also provide a more adhesive surface for additional coatings.
• Hot Dipping
  Also known as galvanizing, this process involves dipping steel into hot zinc to form a coating of zinc oxide layer. This layer is resistant to rust, and will not flake off due to a metallurgic bond between the substrate and the coating. If later welded, the steel must be painted with a zinc paint to prevent rusting of the joints.
• Electroplating
  This process involves immersing a metal component into a bath containing a dissolved metal – typically cadmium, chromium, or nickel – and running an electrical current through it. This coats the item with a thin layer of metallic particles. However, uniform thickness is difficult to achieve with this method, and parts subject to abrasion will need to be repeatedly coated.
• Chemical Process
  Chemical coating is sometimes used for paint priming, metal coloring, and corrosion protection. This method involves creating a thin film of sulfide and oxide on a metal surface though chemical reaction.
• Porcelain Enamel
  This process is popular on cast-iron cookware and restroom partitions, as it protects against both scratches and graffiti.
• Painting
  By far the most popular of the different types of industrial coatings, paints can be applied via a handful of popular methods that we will explore further: e-coatings, powder coatings, and liquid coatings. This is where the bulk of industrial coating occurs, and each method offers unique opportunities and challenges.

Liquid Paint

When it comes to paints, liquid is still beneficial in many cases. In spite of advances in coatings technology, liquid paint remains the optimal choice for several situations, such as when:

• The project requires lower cure temperatures
• A process requires faster color changes
• A project requires more color variation
• Products require special masking
• Smoother coats are desired

The most obvious benefit for wet coatings is probably the fact that this method affords so much color variety. Especially useful in specialty markets, the many shades and specialty coatings create far more choices. Indeed, using liquid paint means you have the option for Teflon and even glow-in-the-dark coatings.

Powder Coating

Some situations require the advantages of powder coatings, a technique which involves electrostatically charging the paint pigment powder to cause adhesion to the substrate. This newer technology is rising in demand, and it’s easy to see why. In addition to producing a more durable coating more efficiently than liquid, powder coating is generally seen as a more environmentally safe option.

The powder coating process allows for little-to-no waste. Any powder not adhered to the target surface is collected and re-used. Because the paint contains no solvents, virtually no Volatile Organic Compounds (VOCs) are released into the atmosphere as the paint ages.

The technology requires less training than other methods, but the associated operation and energy costs are higher. However, this method allows more control over the film thickness. Additionally, this application is an excellent choice where durability and scratch resistance is important. The method is in high demand for applications such as tire rims and oil pipes.

E-Coating

Electrophoretic deposition – also known as e-coating – is the process of dipping substrates into a bath of liquid paint that is then electrified to cause adhesion. This is essentially the liquid version of powder coating. And there are several factors to consider when choosing between e-coating and powder coating.

• E-coating allows for highly targeted coating thicknesses, as the amount of electricity applied determines the film thickness.
• E-coating performs quite well in both primer and topcoat applications; cathodic epoxy electrocoat offers superior adhesion and protection as a primer, while cathodic acrylic electrocoat is a superior topcoat technology for protection against UV rays.
• E-coating more easily coats difficult-to-reach areas as a liquid medium and is thus popular in automotive applications.
• Up-front costs are high with this method, but ongoing operation costs are lower than that of other methods.

CARC Coating

Chemical Agent Resistant Coating or CARC coating is a highly useful specialty coating developed for military use in combat zones. The coating is non-porous and therefore non-absorbent and highly resistant to chemical and biological agents. Additionally, it is that much easier to decontaminate – especially since CARC coatings are typically more durable.

CARC coating is also very useful for camouflage. Its unique pigment package confuses infrared technology – something not known to previous camo coating technology. This means vehicles using this state-of-the-art coating are nearly invisible to infrared cameras.

Choosing the Right Industrial Coatings

As customer expectations As new lighter materials are introduced into the market, corrosion requirements, evolve, regulations and production requirements evolve, it can be difficult to understand which industrial coatings are right for your situation. Rather than swiftly committing to a coating and increasing speed of process to compensate for any gaps, carefully think through these options. Discuss formulation changes, durability considerations, flexibility, and capability in relation to your desired objectives.

There are various types of coatings available for corrosion protection, each with its own unique properties and benefits. The reason for the diversity in coatings is that different types of metals and environments require different levels of protection. Factors such as the metal surface, the environmental conditions it will be exposed to, and the desired longevity of the coating all play a role in determining the most suitable type of coating.
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List of different types of coatings:

1. Epoxy coatings
2. Alkyd coatings
3. Silicone coatings
4. Acrylic coatings
5. DST-PAS

Each of these coatings offers unique benefits and protection against corrosion, making it essential to choose the right one based on the specific requirements of the metal surface and environmental conditions. By selecting the appropriate coating, you can effectively protect metal surfaces from corrosion and extend their lifespan.

Epoxy coatings are known for their exceptional durability and chemical resistance, making them a popular choice for corrosion protection. These coatings are typically used on metal surfaces in industrial settings where they are exposed to harsh chemicals, high temperature, and heavy wear and tear. Epoxy coatings form a strong bond with a metal surface, creating a protective barrier that prevents corrosion from occurring.

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Surface compatibility: Epoxy coatings are suitable for a wide range of metal surfaces, including steel, aluminium, iron etc. They ae commonly used on surfaces that are exposed to corrosive chemicals, water, and extreme temperatures.

Environments: Epoxy coatings are most used in industrial environments where metal surfaces are exposed to harsh conditions, such as chemical processing plants, oil refineries, and wastewater treatment facilities. These coatings are also used in commercial and residential settings for flooring, countertops, and other applications where corrosion protection is required.

Pros of epoxy coatings: 

• Strong adherence to metal surfaces.
• Excellent durability and chemical resistance.
• High resistance to abrasion and impact.
• Easy to clean and maintain. 
• Provides a smooth, glossy finish.
  

 Cons of epoxy coatings: 

• May degrade when exposed to UV radiation.
• Can be prone to yellowing or discoloration over time.
• Requires proper surface preparation for optimal adhesion.
• Can be more costly than other coating options.

Alkyd coatings are known for their versatility and durability, making them a popular choice for corrosion protection on a variety of surfaces. These coatings are oil-based and provide a protective barrier against moisture, chemicals, and environmental factors that can cause corrosion. Alkyd coatings are known for their excellent adhesion properties, making them suitable for a wide range of metal surfaces.

Surface compatibility: Alkyd coatings are suitable for a variety of metal surfaces, including steel, iron, and aluminium. They are commonly used on surfaces that are surfaces that are exposed to mild to moderate levels of corrosion, such as equipment, machinery, and structural components in industrial and commercial settings.

Environments: Alkyd coatings are most used in indoor and outdoor environments where metal surfaces are subject to moderate levels of corrosion. They are frequently used in applications such as machinery, structural steel, manufacturing facilities etc.

Pros of alkyd coatings: 

• Good adhesion to metal surfaces.
• Versatile and suitable for a variety of substrates.
• Excellent resistance to moisture and chemicals.
• Dries quickly and provides a smooth finish.
• Easy to apply and maintain.

Cons of alkyd coatings: 

• Limited resistance to high temperatures.
• Susceptible to cracking and peeling over time.
• Not as durable as some other coating options.
• May require multiple coats for adequate protection.

Silicone coatings are known for their excellent weather resistance, UV stability, and high temperature resistance, making them a popular choice for corrosion protection in harsh environments. These coatings form a flexible and durable barrier on metal surfaces, providing long-lasting protection against corrosion, moisture, chemicals, and extreme temperatures. Silicone coatings are commonly used in applications where high-performance protection is required.

Surface Compatibility: Silicone coatings are suitable for a variety of surfaces, including metal surfaces exposed to extreme environmental conditions, such as roofs, bridges, pipelines, and equipment in industrial settings.

Environments: Silicone coatings are most used in outdoor environments where metal surfaces are subject to harsh weather conditions, UV exposure, and high temperatures. They are frequently used in applications such as industrial roofs, bridges, marine structures, and equipment in chemical processing plants and refineries.

Pros of silicone coatings: 

• Excellent weather resistance and UV stability. 
• High temperature resistance.
• Flexible and durable coating that can accommodate movement. 
• Low maintenance and long service life.
• Provides a smooth and aesthetics finish.

 Cons of silicone coatings: 

• Higher cost compared to other coating options.
• Limited abrasion and impact resistance.
• Requires proper surface preparation for optimal adhesion.
• May degrade over time in environments with high chemical exposure.

Acrylic coatings are known for their versatility, durability, and ease of application, making them a popular choice for corrosion protection on a variety of surface. These coatings are water-based and provide a protective barrier against moisture, chemicals, and environmental factors that can cause corrosion. Acrylic coatings are known for their excellent adhesion properties and resistance to UV exposure, making them suitable for both interior and exterior applications.

Surface compatibility: Acrylic coatings are suitable for a variety of surfaces, including metal, word, concrete, and masonry. They are commonly used on metal surfaces exposed to mild to moderate levels of corrosion, such as structural components, equipment, and machinery in commercial and residential settings.

Environments: Acrylic coatings are most used in indoor and outdoor environments where metal surfaces are subject to moderate levels of corrosion. They are frequently used in applications such as architectural structures, machinery, furniture’s, and decorative metalwork in residential, commercial, and institutional buildings.

Pros of acrylic coatings: 

• Good adhesion to a variety of surfaces.
• Excellent UV resistance and colour retention.
• Fast drying time and easy application.
• Low odour.
• Provide a smooth and attractive finish.

 Cons of acrylic coatings: 

• Limited resistance to harsh chemicals and abrasion.
• Not as durable as some other coating options.
  
• May require multiple coats for adequate protection.
• Vulnerable to hot temperatures and high humidity environments.

The DST-PAS is one of our many exceptional products with focus on functionality for both long- and short-term protection. Whether transporting goods overseas, the DST-PAS effectively shields against humidity and complies with all finishing passivation standards, even functioning optimally at 20°C. Furthermore, our water-based DST-PAS products boast a pH range from neutral to slightly alkaline, meticulously formulated to cater to all metal types while prioritizing a safe working environment. Imagine the convenience of painting directly on parts without the need for additional washing – a reality achievable with DST-PAS. Simplifying indoor storage with its temporary corrosion inhibitor, DST-PAS truly enhances efficiency and ease in your operations.

Pros of DST-PAS: 

• Suitable for all metal types.
• Water-based and enviro-friendly.
• Fast and easy application.
• Functions even at low temperatures.
• Enhances efficiency in operations. 

 Cons of DST-PAS: 

• Requires specialized application procedures and training.
• Temporary corrosion inhibitor.

Application techniques for corrosion protection coatings vary depending on the type of coating, the surface being coated, and the specific environmental conditions. However, some common application techniques used for corrosion protection coatings include:

1. Surface preparation: Before applying any corrosion protection coating, the surface must be properly prepared to ensure adhesion and effectiveness. Surface preparation techniques may include cleaning, degreasing, chemical treatment to remove contaminants, rust, and old coatings.
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2. Spray Application: Spray application is one of the most common methods for applying corrosion protection coatings. This technique involves using a spray gun to atomise the coating material and evenly distribute it onto the surface. Spray application allows for a uniform and consistent coating thickness and is suitable for large surface areas.

3. Dip coating: Dip coating involves immersing the object or component into a tank of coating material to apply a uniform layer of protection. This method is commonly used for small, complex-shaped parts or components that are difficult to coat using other techniques.

Environmental considerations are increasingly important in the selection and application of corrosion protection coatings. As the awareness of environmental sustainability and the impact of the traditional coatings on the environment grows, there is a growing demand for eco-conscious coatings solutions. Here are some key points to consider regarding environmental aspects of corrosion protection coatings:  
 
1. Eco-conscious coatings: Many manufacturers have developed eco-friendly coatings that have lower volatile organic compound (VOC) emissions, reduced toxicity, and are formulated using renewable or recyclable material. Examples of eco-friendly coatings include water-based coatings, powder coatings, and high-solids coatings that have lower environmental impact compared to traditional solvent-based coatings.  
 
2. Low volatile organic compounds (VOC): are chemicals that evaporate into the air, contributing to air pollution and potential working safety. Low VOC coatings are formulated to have minimal VOC emissions, reducing air pollution and creating a healthier working environment during application. 

3. Water-based coatings: Water-based coatings use water as a carrier instead of solvents, reducing emissions of harmful chemicals into the environment. Water-based coatings are environmentally friendly, safe to use, and provide effective corrosion protection for various surfaces.
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