Surface preparation is the foundation of any successful industrial coating project. Without proper preparation, you risk premature coating failure, including adhesion issues, bubbling, peeling, and delamination. This means rework, downtime, and thousands of dollars down the drain.
Fortunately, most coating failures are preventable with proper prep. In this blog post, we’ll cover eight common surface prep mistakes to avoid so you can protect yourself from unnecessary costs.
Why Surface Preparation Matters More Than the Coating Itself
What many industrial facility owners don’t realize is that surface prep often matters more than the coating itself. A coating is only as strong as the surface it bonds to. This means that if you make mistakes during the surface prep process, your coating may not be as durable or long-lasting as it should be.
When this happens, you have to pay to have the coating repaired or replaced. Factoring in labor, materials, operational disruption, safety hazards and liability, damage to your reputation, and compliance issues, you could be out thousands of dollars. There’s a much better ROI when you do it right the first time.
Mistake #1: Inadequate Cleaning of the Surface
One of the biggest surface prep mistakes you can make is not cleaning it properly. When you leave behind dust, oil, moisture, or chemical residue, the coating can’t adhere as well to the surface, causing it to fail prematurely and requiring reapplication.
Proper cleaning may include degreasers, pressure washing, and industrial cleaners.
Mistake #2: Skipping or Rushing Surface Profiling
Surface profiling creates a textured surface for coatings to adhere to and is typically achieved through shot blasting or grinding. If the profile is too smooth or uneven, the coating can’t form as strong of a bond with the surface, resulting in peeling and a reduced lifespan. Keep in mind that each coating type requires a different profile, so it’s important to tailor your surface prep methods to the specific type of coating.
Mistake #3: Ignoring Moisture in Concrete
Moisture vapor transmission can cause bubbling, blistering, and discoloration over time, which is why it’s so important to test the concrete for moisture before applying a coating. Common testing methods include a calcium chloride test and RH probes. Skipping this vital step can lead to widespread coating failure and require costly repairs down the road.
Mistake #4: Failing to Repair Surface Damage First
Coatings cannot hide or fix structural issues. Cracks, pits, spalling, and uneven surfaces need to be repaired before coating; otherwise, they’ll just continue to get worse, causing structural deterioration and repeated maintenance. It’ll have to be fixed either way — it’s much easier and more cost effective to do it before coating rather than after.
Mistake #5: Not Removing Old Coatings Properly
Applying new coatings over an existing coating, especially if it’s already failing, comes with a significant risk of delamination and poor bonding. In some cases, the old coating will need to be fully removed using grinding, blasting, or chemical stripping. In others (like when the old coating is still in good condition), partial prep may be acceptable.
Mistake #6: Overlooking Environmental Conditions
Environmental conditions like temperature and humidity can affect curing and adhesion, and different conditions may require different surface prep methods. Depending on the type of coating you’re applying and whether it’s indoors or outdoors, you may have to plan the project around these conditions. Otherwise, you risk compromised coating performance and a shortened lifespan.
Mistake #7: Using the Wrong Tools or Equipment
DIY attempts using improper equipment are definitely a mistake, often leading to uneven grinding or insufficient blasting. Professional-grade tools — wielded by trained technicians — are the best way to achieve consistent results, ensure the surface is prepped properly for coating, and avoid premature wear.
Mistake #8: Poor Project Planning and Time Constraints
No matter how tight deadlines are, it’s a mistake to rush surface prep to meet them. It can be tempting to skip critical steps to reduce downtime, but the long-term consequences are not worth it. You’re just creating even more downtime for yourself in the future when the coating inevitably needs repairs or replacement.
Reliable Industrial Coating Services by Brush Brothers
At Brush Brothers Industrial, we understand that surface prep is the most critical step in any coating project. We’re known for our attention to detail and promise not to cut corners. When you work with us, you can trust that you’re getting the best, most thorough surface prep possible, saving you money in the long run.
If you’re considering your next industrial coating project, contact us today to get started.