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High solids coatings: A visual breakdown

High solids coatings: A visual breakdown

There’s a lot of talk about high solids coatings among industrial coatings professionals these days. But outside of the circle of experts (and sometimes even within it), the concept can be a little fuzzy. Here’s a visual breakdown that hopefully simplifies main principals at work when we refer to high, or even 100%, solids coatings.

High solid coatings, even higher coverage

What are you really buying with your industrial coatings? The truth is, with low solids coatings, much of the liquid that’s contained in the can will evaporate. Low solids coatings are largely made up of solvents, which exist only to make the actual coating (or “binder”) easier to apply. High and 100% solids coatings, on the other hand, have been engineered to be applied without the help of a solvent.

More mils, fewer coats

Paint specifi­cations usually designate a mil thickness that a coating should reach on the surface of the application. Since solvents evaporate once a coating has been applied (usually as a result of exposure to oxygen), more coating must be applied once a solvent has completely evaporated. This is the difference between the wet ­film thickness (WFT) and the dry fi­lm thickness (DFT) of a coating. A specification aiming for a 20-mil DFT out of a 50% solid coating, for instance, would require two coats at 20 mils, whereas a 100% solid would require only one coat.

Why limit volatile organic compounds?

The Environmental Protection Agency regulates the emission of VOCs through what is known as the Architectural Rule for Volatile Organic Compounds. This rule limits the amount of VOCs manufacturers are able to emit during operation and can result in fees for exceeding the limits.

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High solids coatings: A visual breakdown

VOC regulations and what they mean for manufacturers

VOC limits and manufacturers

Volatile organic compounds, or VOCs, are emitted by everything from aerosol deodorants to household cleaning supplies. But some industries may create them in large enough quantities to constitute a substantial health risk and contribute to ground-level ozone buildup.

According to the EPA, ground-level ozone results from a reaction between oxides of nitrogen and sunlight. It is associated with a host of respiratory issues.

Residents of some large cities, such as Los Angeles or Beijing, are familiar with the buildup of smog over the city skyline. VOCs are a major component of smog. But whereas Los Angeles began to regulate emissions in the 1970s and resulting in a reduction of ground-level ozone levels, Beijing did not enact major air pollution control measures until 2013 and still experiences exceptionally smoggy days.

Inventions like the catalytic converter have been instrumental in cutting pollution, but so too have regulations on the output of VOCs in industrial settings. While VOC regulations may sometimes be a thorn in the side of high-output facilities, they’re nothing compared to the health effects that can result from heavy exposure to ground-level ozone from VOCs.

VOC regulations by state

Coatings manufacturers are limited in the number of VOCs they can include in coatings by the EPA’s Architectural Coating Rule for Volatile Organic Compounds. Enacted in 1998, this subset of the earlier Clean Air Act sets nationwide rules for the manufacture, labeling and packaging of coatings to be used on any stationary structure.

In 2020, the EPA enacted the National Emission Standards for Hazardous Air Pollutants, which establishes emission limits and work practice requirements for new and existing miscellaneous coating manufacturing operations like process vessels, storage tanks, wastewater, transfer operations, equipment leaks, and heat exchange systems. It also implemented the Clean Air Act to require new emission-control techniques under Maximum Achievable Control Technology standards.

Nearly every industry also has its own regulations controlling for VOC emissions. State regulations must meet what the EPA calls Reasonably Available Control Technology (RACT), or the lowest VOC emission levels that can be achieved given technological and economic considerations. Some states and counties go even further. States like Pennsylvania and California have enacted VOC regulations that are far tougher than the EPA’s.

How low-VOC products can help business

VOC regulations don’t have to be the limiting factor in production for manufacturers. OEM and other operations using large amounts of industrial coatings have low-VOC options. These can help keep manufacturers running at full bore.

We’ve written on this blog before about 100% solids coatings. These are coatings that contain no solvents, and hence no VOCs. While these coatings tend to come with a higher sticker price than a similar coating containing VOCs, they also cover a much greater surface area. In many cases, this can make the price difference a relative wash.

Water-based coatings are another option for manufacturing operations to reduce VOC output. While these coatings may have had longer curing times in the past, newer hybrid formulations and other methods of forced curing have largely solved this issue. These products can also help to remove the need to artificially slow production in order to stay beneath VOC emission limits.

If you’re interested in discussing low or zero VOC coatings further, we’d love to talk. You can get in touch with us here.

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High solids coatings: A visual breakdown

How long will my marine coatings last?

Marine coatings durability

Durability is often one of the first topics to come up when discussing marine coatings. How long will this coating last? Given our emphasis on the importance of marine coatings maintenance, it’s something we put a lot of thought into. As with any coating application, a lot of factors go into predicting the lifespan of marine coatings.

When it comes to exterior marine coatings and durability, ship and barge owners have some pretty simple expectations. A good exterior marine coating must have excellent corrosion protection, high UV-resistance (it’s not like tugboats pull into a garage come quitting time), high gloss retention, and solid abrasion resistance characteristics.

Even with these characteristics, the coatings that protect the hulls of barges are faced with an uphill battle. With all the abuse they encounter—from raking against other barges, scraping river bottoms, hitting driftwood and other debris—it’s normally a good idea to maintain these coatings every two to four years, when the barge is dry-docked for maintenance.

Besides the hull, coatings in other areas of a vessel face their own challenges. Non-skid coatings are safety coatings that are popular because they reduce or even eliminate fall hazards in high-traffic areas. But because non-skid coatings are subjected to such heavy foot traffic, they’re susceptible to wear and it’s important that owners keep a close eye on them and pick the best option for their application.

One solution we often recommend is an epoxy-based system, where an aggregate is broadcast onto an initial, wet application and then a topcoat is applied over that. The aggregate can be anything that can be ground up into a fine material that’s still course enough to cause friction. Some of the most common are glass, coal slag and sand. When it becomes apparent that the coating has reached the end of its life expectancy, it should be replaced immediately.

A consultation with a certified coatings professional will leave a barge owner with a much better understanding of how long a coating will hold up under given conditions. This meeting should also work to establish a maintenance plan, which will simplify service schedules moving forward, and give the owner a better idea of how to budget for coatings. The professional should be able to give options at several price points, tips for extending the coating’s lifespan, instructions for proper maintenance of the coating and specific recommendations for how and when to reapply the product.

If you’re ready to talk now about marine coatings for your barges, get in touch with US Coatings today.

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High solids coatings: A visual breakdown

Safety and marine coatings

Coatings are capable of more than just protecting against corrosion. They also play a wider role in making marine vessels safer places to work.

We’ve written before about how, for a fraction of a facility’s maintenance budget, safety coatings can help to cut back on workplace accidents. The same holds true for the marine market. Surfaces are constantly exposed to moisture and become slippery. Going from a bright, sunny deck to a dark cargo hold can strain the eyes. Coatings are especially important in the case of a fire while on the water.

Safety and marine coatings

Making marine work safer

Non-skid coatings are becoming recognized as essential in the marine market.

It’s not hard to see why non-skid coatings are so important. According to Bureau of Labor Statistics, roughly 126 marine cargo handlers reported missing work in 2019 due to slips, trips and falls. Four people suffered fatal injuries in deep sea freight transportation that year.

Beyond preventing wet surfaces from becoming slippery, non-skid marine coatings need to be durable, easy to apply (especially if they’re going to be applied while on the water) and remain functional when subjected to fuel or chemical spills.

Luminescent coatings also have a lot to offer the marine market. Making the transition from sunny conditions above deck to much darker conditions below deck can strain the eyes. Often the pace of work doesn’t allow time to let the eyes adjust. But glow-in-the-dark marine coatings can illuminate obstructions both overhead and underfoot.

Bulkheads, low-hanging ventilation systems and narrow walkways can be made more visible with a solution that’s inexpensive, easy to maintain and also serves as a reliable backup in the case of a power outage. But the most important area for luminescent coatings is the leading edge of the tugboat or barge. In low-light situations, or in the case of a total power outage, an illuminated bow will give the crew and others an idea of the outline of the vessel. This can prove instrumental in avoiding accidents.

Given the potential costs of a fire while on the water, fireproof marine coatings are certainly an option for making vessels safer that should be explored. Intumescent coatings protecting the structural steel of a vessel can make the difference between the outbreak of a small fire and completely losing the craft. If a barge’s normal operations put it at an increased risk of encountering a fire, fireproof marine coatings make obvious sense.

Ensuring that potable water tanks are lined with an NSA-approved tank lining is another essential step in looking out for the wellbeing of crews. This ensures that the fresh water supply is safely contained and free from contaminants that could cause sickness.

Protecting the environment

Booms in domestic oil production increased the rate of oil moving by barge, though it still falls behind pipelines and railroads, according to the Bureau of Transportation Statistics.

The oil traveling our nation’s waterways makes it worthwhile to remind owners that tank linings should be the subject of intense scrutiny. If transporting fuel that was extracted by hydraulic fracturing, a barge’s oil tanks should be equal to the task, lined with a product that can withstand higher concentrations of water.

Unfortunately, the American public is all too familiar with oil-related incidents on our waterways. So talk to a coatings professional about the state of your barge’s tank linings and ask about how a marine coatings maintenance plan can help to simplify the upkeep, while protecting against costly incidents.

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High solids coatings: A visual breakdown

Simplifying marine coatings maintenance

Barge paint / marine coating maintenance

Keeping a barge in shape to run rivers is no easy task. During its life of ferrying goods up and down waterways, a barge is constantly encountering driftwood and other debris in the water. Its hull regularly scrapes the river bottom. It’s also guaranteed to spend a large amount of time moored to other barges, where a rising and falling wake leads to a lot of bumping and raking for it and its neighbors.

On its interior, the barge is subjected to regular loading and unloading of cargo which can cause impact damage in the case of dry goods, or pitting and rusting in the case of corrosion caused by liquids. On top of all that, tugboats are expected to support the living needs of a crew that spends long stints aboard while working the river.

Given the constant motion of both cargo and crew, it’s no surprise that regularly scheduled maintenance is a critical part of extending the service life of a vessel. At regular intervals, key components such as engines, pumps and generators need to be checked to make sure they’re working properly. The marine coatings that protect barges and tugboats are no exception.

Marine coating maintenance conundrum

When it comes to tracking the life cycle of each vessel’s coating system, there’s a lot to keep in mind:

  • Which areas of the barge or tugboat were last painted?
  • What type of marine coating was used on the area?
  • Was the deck painted with a non-skid coating?
  • What sort of chemical resistance was required of the coatings used to line the barge’s storage tanks?
  • Have potable water tanks been lined properly?
  • Is the marine coating deep enough into its service life that it needs to be replaced before the asset is put back into service?

Now imagine you’re in charge of this routine for a fleet of barges that numbers upwards of 100. A task that required diligent work for one barge is an enormous logistical burden for an entire fleet.

Luckily, there are ways individuals in charge of marine coatings can make things easier on themselves. It’s possible to get together with a coatings manufacturer to design a coating that perfectly coincides with the other facets of a barge’s maintenance schedule. Say a barge is dry-docked periodically for scheduled maintenance, a coating can be designed with exactly that intended service life. This way, a given maintenance task can also serve as a reminder that a coating’s service life is up.

US Coatings can also provide total asset analysis tracking along with its coatings. This enables us to keep tabs on every aspect of your marine coatings maintenance schedule. We can remind you when coatings were applied, what area they were applied to, the product specifications and alert you when a coating is nearing the end of its service life, for every vessel in your fleet. With digital record keeping of the fleet’s coatings maintenance schedule, it’s possible to look up when work was last done on a vessel and when it’s next scheduled to receive service. It’s our way of simplifying the way you do marine coatings maintenance.

Let’s get started

For a consultation on simplifying you marine coatings maintenance operation, get in touch with us today. We can talk coatings specifications, tracking your coatings and formulating a budget so your marine coatings are never the cause of future surprises.

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High solids coatings: A visual breakdown

Tank linings in the age of hydraulic fracturing

The advent of hydraulic fracturing has brought with it rapid economic growth and the previously undreamed of promise of energy independence for the United States. It has also completely changed the way the storage and transport of crude oil is approached.

Most owners of crude oil storage tanks, and the railroad tank cars that transport it, have recognized that fracking introduced many aggressive chemical components to the crude oil that previously got along pretty well with steel. Those that haven’t come to this realization find themselves at an increased risk for the sort of corrosion and pitting of storage tanks and tank cars that invite spills and significant environmental degradation.

Tank linings in the age of hydraulic fracturing

The issue

Corrosion is the result of oxidation, which can’t occur except in the presence of oxygen and water. With traditional methods of oil extraction, some water was present in the crude oil, but usually in trace amounts and suspended in the oil where no oxygen was able to reach it.

As a result, for the vast majority of the time humans have been extracting crude oil from the earth, the storage tanks and transport vessels used to move it did not need to be lined with protective coatings. Storage tank owners could save money by not lining their tanks, with minimal risk of corrosive damage ever being a problem. To this day, it’s not unheard of to encounter companies still requesting that railcar manufacturers not line the inside of their cars.

Fracking has forced a change. Because drastically more water is used in the process of hydraulic fracturing, greater care needs to be taken to protect against corrosion. While transporting oil obtained by fracking, water and oxygen are both abundant, meaning corrosion is once again on the list of concerns for owners of storage tanks and railroad tank cars.

Not just the hotspots

Storage and transport of crude oil obtained by fracking is not just a concern for owners operating near traditional hotspots of extraction like Texas, the Dakotas and the Gulf Coast. Storage tanks are commonplace across the United States, holding newly extracted crude as it makes its way to refineries, where still more storage tanks hold it while the crude waits to be refined.

Given the current scale of fracking operations across the United States, if only ten percent of owners have not upgraded their tank linings to address this reality, there are an enormous amount of storage tanks vulnerable to pitting, corrosion and leaks.

Crude’s journey, too, has prompted concerns over the safety of transporting by rail. Some estimate that over 1 million barrels of oil are being extracted per day, and that 9 million barrels are riding the rails at any given moment. A standard railroad tank car can hold about 740 barrels.

If railcar owners want to help protect against legal action, there’s no reason the latest railcar linings shouldn’t be a part of that strategy. As a part of stricter regulatory legislation that is in the works, there should be at least some attention paid to minimum standards for railcar linings.

And then there’s the water

Fracking is a water intensive enterprise. By some estimates, somewhere between 70 billion and 140 billion gallons per year are required. Some are searching for a process to recycle this “frack water,” while others believe it’s best disposed of by pumping it into deep underground wells.

Whatever solution emerges, storage and transport of this byproduct will become an increasing concern for as long as fracking keeps up its current pace. This presents a problem. The chemical blend used in frack water is regarded as proprietary by the companies who use it.

Without knowing exactly what they’re protecting against, coatings manufacturers can’t stand by the tank linings they supply to protect assets. Certain variables make it more difficult to predict which products will be effective. If the byproduct still contains rock debris or other abrasives, for instance, an additive such as flake glass may lead to better performance.

Without knowing the exact composition of the substance these tanks are holding, coatings manufacturers cannot guarantee a given product will provide adequate protection. Companies in charge of storing and transporting this wastewater should therefore be closely investigating the tank linings they use, making sure they’re up to the task.

Tank linings systems guide

We want to simplify the process of selecting linings for both storage tanks and railroad tank cars. To do so, we’ve put together a guide complete with system selection guides, chemical resistance charts, data sheets, case studies and more. You can download it by clicking the link below.

 

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High solids coatings: A visual breakdown

How to prevent corrosion under insulation

We’ve previously discussed the basics of high temp coatings, which are often used in process facilities such as refineries, oil and gas, and petrochemical plants. These coatings protect pipe systems that transport various materials at high heat.

These hot pipes are usually covered with a layer of insulation to increase efficiency, protect personnel and capitalize on energy savings. Unfortunately, it also helps create one of the most vexing corrosion problems in the industry: corrosion under insulation.

Corrosion under insulation of steel pipes

What causes corrosion under insulation?

Corrosion under insulation, or CUI, occurs when moisture enters through holes or cracks in the insulation and becomes trapped against the hot pipe. Prolonged moisture exposure can cause rapid rusting and corrosion on the pipe’s surface.

Since the layer of insulation completely surrounds the pipe, corrosion under insulation often goes unnoticed. When the insulation is finally stripped from the pipe, either to investigate a problem or as part of a scheduled replacement, facility managers sometimes find the pipe to be completely ruined.

What to do about corrosion under insulation?

The insulation surrounding a pipe must be completely enclosed to prevent CUI. Joints, terminations and other irregularities along the length of the pipe should be carefully sealed. However, moisture can still penetrate insulating layers.

There isn’t a perfect solution for corrosion under insulation, but it can be mitigated by regularly checking the piping under insulation often as a part of a scheduled coatings maintenance plan, sealing insulation with care, and most importantly, choosing a top quality high temp CUI coating.

It’s important to verify that the coating you choose has been specifically designed to stand up to high temperatures and to defend against corrosion under insulation. Also, that it is designed to withstand the range of temperatures the substrate will subject it to.

When chosen to match these criteria, high temp CUI coatings are the most effective method for fighting corrosion under insulation in process facilities.

Contact US Coatings for help in creating a system to protect your insulated assets for the long haul.

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High solids coatings: A visual breakdown

The benefits of high solids coatings for railroad tank cars

According to the American Association of Railroads, there are currently over 430,000 railroad tank cars in service. The vast majority of these cars are not owned by railroads, but leased by private customers who use them to transport their products. Many of these lessees encounter a similar problem with their tank cars. It has to do with the percent solids of the coatings used to protect them. For a refresher on the percent solids of a coating, check out this post we wrote on 100% solids coatings.

railroad tank car coatings

Due to the cylindrical shape of tank cars, and gravity, it’s more difficult to achieve the desired film build on the top of the tank, often leading to an unevenly applied coating. During its service life, this top portion of the car will be prominently exposed to repeated rain and harsh sunlight. Eventually, the stress leads to a problem known as “blooming,” or rusting on the top of the tank car. “Redheads,” as cars with this problem are known in the industry, are a good indication that something went wrong during the coating application process.

How to prevent rusting on the top of a tank car

This problem can be avoided by using coatings with a higher percent solids. With fewer solvents flashing off, the coating dries more quickly and it’s easier to achieve high film builds on the top of the tank. The end result is a coating that’s more evenly distributed over the entire tank car. But that’s not the only benefit of using a higher solid coating.

Coatings that contain higher solids by volume also allow a shop to purchase less material to cover a given square footage. If a typical 60 percent epoxy has a theoretical coverage rate (where no loss occurs during the application) of 190 square feet applied at 5 mils DFT, an 80 percent solids version would have a theoretical coverage rate of 260 square feet applied at 5 mils DFT. The result is 27 percent less product that’s capable of covering the same area.

How to limit VOCs

Higher solids coatings also significantly cut down on the amount of volatile organic compound (VOC) and hazardous air pollutant (HAP) byproducts. Lower levels of evaporating solvents mean fewer VOCs are released into the atmosphere, and into the shop. For large-scale operations VOCs can add up quickly, making cutting back on these substances necessary to avoid fines. Tighter regulation of VOC outputs may increase the importance of alternative choices in the near future.

Some attempt to completely take VOCs out of the equation with water-based coatings. But this approach also has its drawbacks. They take longer to cure, potentially causing backups in the shop. Properly accounted for, this strategy can be a viable solution. But like we’ve talked about before, the best solutions draw on a number of key features.

A balancing act

Ideally, the right product will offer a balance of these key features. It should have relatively high solids by volume for film build, and low VOC output to ensure that the shops where it is applied adhere to environmental standards. It should be able to be applied efficiently and in a timely manner. And of course, it must be a cost-effective solution. Click the link to read more about our railcar coatings, or visit our tank linings page for more on linings.

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High solids coatings: A visual breakdown

Choosing the right railcar coatings

Choosing a railcar coating

There are a lot of options out there when it comes to choosing the best coatings to protect the railcars you own or lease. So how should you know which one to choose?

When it comes to selecting the right product to protect your cars, it’s best to consider your goals for the coating. How long do you expect it to last? How much time do you expect to spend applying it? What sort of abuse do you expect it to withstand? The answers to these questions will provide a good basis for your strategy moving forward.

If you’re expecting a long life cycle for your coating, it goes without saying that a more durable product is in order. But if you know the railcar is brought in every five years for scheduled maintenance, it may not make sense to go with the most durable multi-coat finish when a sufficient, single-coat system could do the job at a lower cost.

Many shop owners worry about long curing times causing a bottleneck in their facilities. Situations like these make single-coat systems attractive. After a sandblast, the railcar can be painted and then moved on down the line, therefore avoiding longer cure times. Epoxy coatings may cure more quickly, but may not be suitable if long-term UV protection is needed.

It is especially important to consider a tank car’s intended use where linings are concerned. The longer handling times associated with baked-on phenolics may be unavoidable if product purity is a concern. Since discoloration, odor or other interactions with the coatings system are unacceptable in the transport of food-grade items or sulfuric acid, a baked-on phenolic will likely be the best bet.

The importance of choosing the correct tank car lining has increased with the prevalence of hydraulic fracturing as an energy extraction method. Since water often accompanies this method as a byproduct, care must be taken to ensure that water, settling at the bottom of the tank, does not corrode and pit the steel. When leasing a tank car, this sort of damage could substantially increase maintenance costs upon returning the car. This is a concern tank car owners have only recently had to consider. There are also significant benefits of high solids coatings for these railroad tank cars.

Choosing the right railcar coating is all about how you expect it to perform. It’s important to consider your expectations for service-life, coating application time and the intended use of the railcar. Once an owner has decided what aspects of performance are most important, then choosing the coating that will provide those benefits becomes that much easier. Visit our railcar coatings page for more information.

 

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High solids coatings: A visual breakdown

The importance of having a coatings maintenance plan

The facility managers we see operating without an industrial coatings maintenance program tend to be those who have never been burned by not having one. It’s telling that those who have encountered problems from expecting coatings to outperform their service life don’t make the same mistake twice.

Neglecting the coatings that protect your assets from corrosion and other damage means gambling in a high-stakes game. Here we’ll take a look at the most common reasons for not having a proactive maintenance plan in place, and how that will come back to hit owners and facility managers right in the wallet.

Playing with fire

Many owners aren’t considering a plan for coating maintenance right from the outset. The last thing on an owner’s mind when moving into a new facility is the day the coatings will outlive their service life. But having a plan in place before that day comes can save a lot of headaches, and money.

Other times, high turnover within a corporation leads to the organization losing track of when a facility’s coatings should be undergoing maintenance. These organizations often find themselves operating without a coating maintenance plan, instead only handling issues as they arise. This process continues until a proactive manager comes along and wonders if there is a way to address problems periodically or incrementally to avoid having to replace equipment or undergo large-scale facility overhauls.

The burn

By not maintaining the coatings that protect their assets, owners and facility managers invite the sort of damage that can to get expensive. Take the all-too-frequently-true example of a neglected bridge. It receives a three-part, zinc epoxy urethane coating with an expected service life of 25 to 30 years. Now imagine funding for the scheduled maintenance falls through and the bridge’s coatings system is not revisited until it is deemed “structurally deficient” years later.

By now, corrosion has led to significant structural damage. Significant portions of the structural steel need to be replaced. New members must be fabricated to complete the rehab. Significant costs are added in the form of repairs, material and unplanned downtime. Only then is the whole bridge ready to be blasted and repainted.

As coatings wear off, corrosion begins to attack the asset. Once this process is underway, assets are continuously devalued until they eventually need to be replaced. Having a maintenance program in place to properly protect your assets is a great way to ensure this process never gets started.

Financial concerns are just one aspect of a failed coatings system. Neglected coatings can also pose serious safety risks. Bursting pipes, structural collapses, explosions and the like are some of the catastrophic repercussions of a poorly maintained asset. While a new coatings system may not be the remedy for serious structural damage, a maintenance plan will often lead to the discovery of such an issue. The damage can then be addressed properly before an accident occurs.

The payoff

If pushing your industrial coatings beyond their service life is a risky gamble, investing in a coatings maintenance plan upfront is a safe investment. Unfortunately, many owners and facility managers are under the impression that a maintenance plan will automatically involve sinking a boatload of money into their facility all at once. This misunderstanding keeps them from acting on developing a program for their facility.

When properly thought out, a maintenance program doesn’t need to work this way at all. Under the right direction, the plan will align with the owner’s budget and goals.

This happens by approaching maintenance in two steps. Immediate problems (such as a leaking storage tank) are dealt with immediately. Secondary problems (such as fireproofing an entire facility) are then scheduled out over the course of the plan. This way, the cost of the plan is absorbed over time and the huge expense of a total asset failure is avoided.

As with many of the services we offer, there are firms that specialize in designing coating maintenance programs. They will inspect your facility or equipment, write you a recommended plan of action, and then potentially charge you upwards of tens of thousands of dollars for their services.

At US Coatings, we see this service as a chance to build relationships. To talk about designing a maintenance program for your facility, free of charge, get in touch with us today.

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