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Industrial Coatings Industry: Maintenance, Removal, & More

 

 

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What are industrial coatings

Industrial coatings are specialized, high performance coatings, paints, or finishes applied to surfaces to protect and enhance their performance in various industrial settings. These coatings are designed to safeguard materials like metal, concrete, wood, and plastic from damage caused by environmental factors such as moisture, chemicals, UV radiation, and physical wear. Common types of industrial coatings include corrosion-resistant coatings, heat-resistant paints, and anti-slip finishes. They are widely used in industries such as construction, automotive, manufacturing, and infrastructure, providing critical protective barriers for machinery, equipment, pipelines, and structures.
  • Epoxy Coatings: Known for chemical resistance and strong adhesion, epoxy industrial coatings are commonly used in industries like manufacturing to protect steel and concrete surfaces from wear and chemical damage. These industrial coatings are also widely used as floor coatings in industrial facilities. Read more about how to remove epoxy in this blog. 
  • Polyurethane Coatings: These coatings are flexible and highly resistant to abrasion, making them ideal for applications in automotive parts, machinery, and outdoor equipment. These types of industrial coatings provide long-lasting protection against wear, chemicals, and UV light degradation.
  • Zinc-rich Primers: Often used in steel structures, such as bridges and pipelines, zinc-rich primers provide robust corrosion protection by acting as a sacrificial barrier, preventing rust formation and extending the life of the underlying metal.
  • Acrylic Coatings: Acrylic coatings offer specialized weatherability, UV resistance, and color retention, making them ideal for use on outdoor signage, decorative finishes, and architectural coatings.
  • Intumescent Coatings: These coatings expand when exposed to high heat, creating an insulating layer that protects structural steel from fire damage. They are commonly used in buildings and industrial plants for fireproofing purposes.
  • Polyurea Coatings: Known for their rapid curing time and extreme durability, polyurea coatings are used in applications that require high resistance to impact, chemicals, and abrasion, such as in mining equipment, water treatment plants, and tank linings.
In addition to their protective qualities, industrial coatings can also improve the aesthetic appearance of a wide array of products or surfaces. Depending on the intended application, these coatings may offer additional benefits like electrical insulation, fire resistance, or anti-fouling properties for wet or other marine environments. 

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Who Uses Industrial Coatings

 Industrial coatings are used by a wide range of industries that require protective, durable, and functional finishes for their equipment, infrastructure, and products. Manufacturers in sectors such as construction, refineries, and energy/oil rely on industrial coatings to extend the lifespan, improve resistance to wear and corrosion, and improve the overall durability and safety of their assets.
 
Plant maintenance, which involves the upkeep of refineries and industrial facilities, is essential for minimizing equipment failures, maximizing operational uptime, and ensuring the long-term reliability of industrial assets. A key aspect of this maintenance is managing the integrity and performance of industrial coatings, which protect equipment from corrosion, chemical damage, and wear. Some examples of industrial coatings for plant maintenance include epoxy coatings, polyurethane coatings, and zinc coatings.
 
Offshore oil rig components in the energy sector, are constantly exposed to highly-corrosive saltwater, humidity, and the open-ocean elements. Corrosion is a constant threat, and maintaining operational safety and efficiency is a never-ending challenge in drilling rig maintenance. To combat this, rigs often rely on protective industrial coatings such as epoxy coatings for their strong chemical resistance, aliphatic polyurethane topcoats for weather resistance and durability, and zinc-rich primers for their superior corrosion protection. These coating materials play a crucial role in preserving the durability and functionality of offshore equipment, ensuring the structure can withstand the harshest environmental conditions.
 

How to Remove Industrial Coatings

 Removing industrial coatings is essential for maintaining the integrity and performance of surfaces that have become damaged, corroded, or worn over time. This process allows for the application of new protective layers, ensuring surfaces remain resistant to environmental factors like moisture, chemicals, and UV damage. Coating removal also improves adhesion for new finishes, enhancing surface longevity. Signs that it’s time to remove coatings include visible damage such as cracking, peeling, or flaking, corrosion or rust beneath the coating, and fading or discoloration. If the industrial coating no longer meets functional needs or has reached the end of its service life, it should be replaced to prevent further damage and maintain the equipment’s performance. 
 
 To remove industrial coatings and other high quality coatings, the process typically involves several steps depending on the type of coating and the surface it's applied to. The most common methods include:

  1. Abrasive Blasting/Dustless Blasting: This involves using materials like sand, glass beads, or steel grit to blast off the industrial coating. It's effective for thick layers of coating and works well on metal surfaces. Sandblasting or media blasting is one of the most common methods for surface preparation before applying new coatings.

  2. Chemical Stripping: Chemical removers, such as paint thinner or solvents, can dissolve coatings, making them easier to scrape or wipe off. Chemical adhesive removal or paint thinner is often used for more delicate substrates where abrasive methods might cause damage or when dealing with soft substances such as uncured epoxy.

  3. Heat Stripping: Using heat to soften coatings can make them easier to remove. Heat guns or propane torches are commonly used for this, though care must be taken not to damage the underlying material. 

  4. Mechanical Methods: Scraping, sanding, or grinding can be used to remove coatings manually or with power tools. This is typically slower than blasting or chemical methods but may be necessary for smaller or more precise areas.

The method you choose depends on the coating type, the substrate material, the environment, and the size of the job. After removal, it's essential to thoroughly clean the surface to ensure proper adhesion for high quality coatings.

 

Preparing a Surface for New Coatings

Once the old coating is removed, proper surface preparation is essential for ensuring high quality coatings and to enhance durability during the application process.

  1. Start by thoroughly cleaning the surface to remove dust, grease, oil, or contaminants using appropriate cleaners or degreasers.
  2. If the surface is steel, be sure to remove any mill scale, a layer of oxide that forms from chemical processes during manufacturing, as it can prevent proper adhesion. Removing mill scale can be removed through abrasive blasting or grinding.
    Removing mill scale with dustless blasting
  3. Next, check the surface profile—if it's too smooth, use abrasive blasting or sanding to create the right roughness for adhesion.
  4. Remove any rust or oxidation with wire brushing or chemical rust removers.
  5. Ensure the surface is completely dry before applying any coatings to prevent moisture-related issues. If necessary, apply a primer to improve adhesion and corrosion resistance, then allow it to cure fully.
  6. Finally, perform a final cleaning with a tack cloth to remove any remaining debris before applying the new coating according to manufacturer guidelines, ensuring optimal conditions for curing and adhesion.

 

Industrial Sandblasters for Coating Removal

One of the most efficient ways to remove industrial coatings is with an industrial sandblaster or dustless blaster.  These machines use abrasive materials—like garnet, crushed glass, or coal slag—blasted at high velocity to remove rust, corrosion, and industrial coatings, preparing surfaces for new finishes or repairs. Not all blasters are created equal, what sets each machine apart comes down to a few key factors: volume capacity, the air compressor they’re paired with, and the versatility and mobility of the blasting setup. 

Industrial sandblasters have larger drums to hold maximum volume of abrasive or an abrasive and water mixture. This drastically cuts down on time between machine refills and keeps operations efficient. Industrial sandblasters require compressors with higher CFM ratings to maintain consistent pressure, higher PSI to effectively strip thick coatings or corrosion, and a continuous duty cycle for non-stop operation to ensure reliable performance during demanding projects. 

When it comes to versatility and mobility of sandblasting setups, Dustless Blasting is industry-leading. With wheeled blast pots, compressor-ready solutions, and comprehensive trailer-mounted units, our sandblasters make it easy for operators to transport their machine to remote job sites and offer maximum versatility with the ability to wet, dry, and soda blast in one machine. Whether you're working on steel structures, offshore rigs, or in a refinery, our industrial sandblasters are built to make coating removal and other surface preparation faster, safer, and easier. 

 

Industrial mobile dustless blasting
Industrial sandblasting
Industrial sandblasting surface preparation for industrial coatings
Heavy-duty blast pots

How to Succeed in the coatings industry

The coatings industry offers numerous opportunities, but thriving in this competitive field requires more than just technical expertise—it calls for versatility. Key factors shaping the industry include globalization, corporate consolidation, and the need for innovative solutions. Whether you're an experienced professional or just launching your coatings business, one of the most crucial elements for success is mastering both the removal of old coatings and the precise application of new ones.

Visit this blog to learn more about how to master your skills and find success in the industrial coatings industry. 

Industrial Coatings industry FAQs

What About failed polyurea lining removal?

Polyurethane linings are commonly applied to metal, concrete, or other surfaces to protect against corrosion, chemical exposure, abrasion, and extreme temperatures, particularly in industries like mining, wastewater treatment, and oil and gas. Without proper preparation or maintenance, this lining can start to pull away from the surface it has been applied to. The removal process typically involves using specialized abrasive blasting techniques, such as wet blasting or soda blasting with Dustless Blasting, to gently remove the old lining without compromising the surface. In some cases, chemical stripping agents may also be used to break down the polyurethane, making it easier to peel off. 

How Do I remove Bed liner?

 Bed liner removal depends on the type (spray-on or roll-on) and the condition of the underlying surface. Spray-on bed liners are generally more durable and are best removed using abrasive blasting, which efficiently strips the material. For roll-on bed liners, the process typically involves using a heat gun or torch to soften the material, followed by scraping to lift it off. In some cases, a combination of these methods may be used to achieve the best results. The choice of removal technique will vary based on the bed liner's type and the surface condition, ensuring the most effective and damage-free removal.
 
Bed Line removed with dustless blasting Failed bed liner
What are industrial powder coatings?
Industrial powder coating is a dry finishing process where a powder, made of resin and pigments, is electrostatically applied to metal and other materials. The coated item is then heated in an oven, causing the powder to melt and form a durable, smooth finish. Powdering coatings provide and enhance durability to corrosion, scratches, and wear, making it ideal for items like automotive parts, machinery, and outdoor equipment. Powder coatings are also more environmentally friendly than other coatings, as it produces less waste and contains no solvents.
 
What is the process of removing mill scale?
Removing mill scale is crucial to achieve strong, corrosion-resistant, and visually appealing results before applying industrial coatings. There are several methods for removing mill scale, each suited to different project sizes. Abrasive blasting is effective for large-scale projects, using materials like crushed glass or garnet to blast away and remove mill scale and rust. For smaller projects, grinding with power tools such as discs, wire wheels, or rotating brushes can also remove mill scale, though it is time-consuming and labor-intensive. Pickling, or chemical removal, involves immersing steel in acid baths like hydrochloric or phosphoric acid to dissolve the scale, with white vinegar being a good option for small-scale jobs. Finally, flame cleaning, which uses a torch to burn off the mill scale, is less commonly used but can be effective in certain situations.

UPGRADE YOUR SURFACE PREP WITH DUSTLESS BLASTING

Dustless Blasting is at the forefront of the mobile blasting and cleaning industry, offering a dynamic way to control your future and operate a versatile on-site service. Inspired by the substantial potential and demand in the mobile paint stripping and cleaning industry—which is valued at over $10 billion annually and growing—here's why the Dustless Blasting surface preparation method is a preferred choice for providing customers with industry-leading results:

  1. Revenue and Demand: Everything around us is painted, rusty, or dirty, and while the demand for cleaning services has a global reach, the supply of providers can be limited, presenting a lucrative market opportunity.

  2. Cost-Effective and Quick Start: With our comprehensive mobile systems, you can start your business or add to your existing operation as soon as you drive off the lot. Get a fast track to generating revenue with high margins with no ongoing fees or royalties.

  3. Scalability and Support for Startups: The business model supports easy scalability, allowing for expansion through additional trailers and crews. Plus, you gain the advantages of community support, marketing tools, and a reputable brand without the burden of franchise fees.

  4. Versatility: Whether you're launching a new venture or expanding an existing one, Dustless Blasting is a smart investment and preferred choice for many surface restoration pros. It's highly adaptable, capable of handling diverse jobs across multiple industries so you can jump into providing customers a one-stop-shop without the use of harsh chemicals.

Next Steps

Ready to take the next step with a versatile, cost-effective dustless blaster? Download our product catalog below or book a meeting with our blast experts to start blasting today!

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