More Than Just a Coat of Paint: The Science of Industrial Coatings

When it comes to industrial projects, the job is far more complex than applying a fresh coat of paint. Unlike the latex paints used in homes, industrial coatings are often two or three-part urethane or epoxy products that are "chemically-cured." For these coatings to properly cure, the environment—including temperature and humidity—must be precisely controlled. And that is a greater challenge than you might think.

Controlling the Environment, From Substrate to Air

On a typical industrial project, we are painting concrete or steel, and the temperature of these materials is rarely the same as the ambient air temperature. For example, steel in direct sunlight can be 40 degrees hotter than the air around it.

To achieve the perfect conditions, we often construct an entire "bubble" around a project using scaffolding and shrink wrap. This custom-built isolation booth allows us to completely control the environment, regardless of the weather outside. We then use indirect heat sources, dehumidifiers, and explosion-proof ventilation fans to maintain the exact temperature and humidity needed for a flawless cure.

A Real-World Example: Painting a Cooling Tower

Consider a project to paint a cooling tower on the side of a building. These towers use falling water, which creates a constant, high-humidity environment. To prepare the surface for painting, we must first abrasive-blast the steel down to the bare metal. This process requires us to keep the humidity at an absolute minimum to prevent immediate rusting.

The challenge is immense: we must build a completely weather-proof and rugged containment around the tower, all while the client continues to use it without any interruption to their production. This level of environmental control and precision goes far beyond what most people imagine when they think of painting and is a perfect example of how our team goes further beyond the brush.