A surface coating is only as good as the surface coating preparation and the

environmental conditions throughout the process. Without the ideal coating

materials and ambient conditions, the coating material might fall victim to
corrosion or fail to adhere to a substrate correctly. Since premature failures are
generally the result of preventable circumstances, knowing what to monitor and
consider will help ensure a successful coating application, prevent timeline
delays and avoid budgetary problems.

Why a Surface Coating Fails

Improper surface coating preparation: Even when using a coating that’s suitable for
the intended environment, a substrate’s cleanliness affects the coating’s performance.
The goal of surface coating preparation is to free the substrate of contaminants, such
as:

- Weld splatter and fumes

- Oxidation
- Oil
- Dirt, dust and other particulates
- Salts
- Welding burn-through
- Ionic species
- Moisture

The best method for cleaning a substrate depends on its composition, age, the
contaminants found on its surface, and the type of coating that already exists on its
surface.

Lack of monitoring: Successful coatings require constant monitoring and control of the
ambient conditions from the moment that the surface preparation tasks begin to at least
48 hours after applying the final coat. If conditions do not remain ideal between the
cleaning and coating process or between each coating, the surface is at high risk for
contamination and oxidation.

Uncontrolled temperatures and relative humidity levels: In general, the best

temperatures in which to apply a surface coating are between 56°F and 99°F,
depending on the coating type and manufacturer’s instructions. Temperatures that are
too hot cause coatings to dry too quickly, while lower air temperatures delay drying and
curing times.

Inadequate surfacetemperatures: During the day, a surface may absorb heat, making
it hotter than the air’s temperature—similar to a metal slide on a summer day. At night,
the surface will radiate the heat that it absorbed. The temperature changes affect the
coating’s adhesion and promote the formation of condensation. Resulting problems
include catering, pin holing, blistering and oxidation. Depending on the dew point,
surface temperatures should match the manufacturer’s specifications and air
temperatures, which should remain constant throughout the process.

Poor ventilation: A lack of ventilation leads to the accumulation and entrapment of

solvents, which negatively affect coating applications. It may also promote oxidation and
mold growth. It is best to use a forced ventilation system during the surface preparation
and coating processes, and for at least 48 hours after the final coating application.

The weather is unreliable and HVAC systems cannot effectively provide adequate
conditions for surface coating projects. The best proactive approach to meet deadlines,
stay within budget and ensure the success of a surface coating is with Polygon’s
temporary humidity control solutions. Specialist’s custom design the equipment for your
exact needs to give you the ultimate control over ambient conditions and keep your
crew productive. Get in touch with Polygon today to learn more and schedule a
complimentary consultation.

Applying specialist protective coatings to structures and assets during the winter
months can pose many challenges, as many coatings need to be applied at a specified
temperature. As temperatures continue to plummet across the UK, CSC Services look at
the top 10 reasons why coatings fail:

1. Applying to a dirty surface

Dirt, grease, dust and other surface latents will form a barrier between the substrate and
coating to be applied which means there is no mechanical bond present.
2. Lack of preparation
Surfaces need to be grit blasted or hydro blasted to form a mechanical key.
3. Incorrect substrate surface preparation
Correct substrate surface preparation involves correct application of pore fillers and fairing
coats to address blow holes or honey combing in concrete surfaces. Fairing coats need to be
applied correctly to leave the required surface profile.
4. Using the wrong product
You should always use a specialist contractor to advise on coatings for specific
environments. Some products have high abrasion resistance, tensile strengths and high
elongation properties. Using a high tensile strength coating with no elongation properties on
a substrate where movement may occur will result in cracks and failure in the coating.
5. Lack of product knowledge
A lack of specialist knowledge may result in incorrect mixing of products. Most industrial
products are two pack systems. If they aren’t mixed correctly they will not cure correctly.
6. Using an incorrect application method
Some products need specialist equipment to apply. Some products require a brush, roller or
spray only.
7. Application at an incorrect temperature
If the application surface is too cold (or in some cases too hot) the product can’t be applied
as it will not gain the correct adhesion.
8. The wrong curing temperature
Various products require certain environmental conditions. Dew points, temperature,
humidity, and air flow need to be considered to avoid condensation causing a failure in the
curing process.
9. Insufficient curing time
Coating products require a certain amount of time to chemically bond as per data sheets.
Not leaving sufficient time may mean the product fails.
10. Poor after-care
After curing, the product should be fully cleaned and inspected for fails. A scheme of
programmed appropriate after-care and inspections should be scheduled.