10 Industrial Coating Types and Their Uses

Industrial coatings protect surfaces from damage, corrosion, and wear. Using the right coating helps extend the life of materials, improve performance, and reduce maintenance costs.

This guide will explain what industrial coatings are, why they matter, and the common industrial coating types.

What are Industrial Coatings?

Industrial coatings are special protective layers applied to surfaces like metal, concrete, or plastic. They shield against moisture, chemicals, heat, and physical impact.

Some coatings also improve appearance or provide insulation. You see them on metal structures, machines, equipment in factories, bridges, pipelines, and even aerospace parts.

Benefits of Industrial Coatings

Using industrial coatings offers several advantages, including the following:

• Protects metal from rust and oxidation.
• Shields surfaces from acids, solvents, and other harsh chemicals.
• Reduces damage from friction, impact, and abrasion.
• Withstand extreme heat or cold.
• Enhances the look of surfaces with colors or finishes.
• Prevents water damage and leaks.
• Helps prevent short circuits and electrical failures.

Industrial Coating Types

These coatings come in different types, each designed for a specific purpose. Below are some common industrial coating types which are discussed in detail.

Epoxy Coating

Epoxy coating is a protective layer made from a resin and a hardener. Once applied, it enhances mechanical properties and chemical resistance.

Epoxy coatings work well on metal, plastic, wood, bricks, ceramics, and concrete. However, they do not adhere to materials like silicone, vinyl, rubber, parchment, and wax.

How Epoxy Coating Works

Before applying epoxy, the surface must be cleaned to remove contaminants like dust, oil, and grease. The resin and hardener are then mixed according to the manufacturer’s instructions. The mixture is applied using a brush or roller and then cured to form a hard protective layer.

Pros of Epoxy Coating

Epoxy coatings are highly durable, offering excellent resistance to wear, impact, and abrasion. They are also resistant to chemicals such as acids, alkalis, solvents, and petroleum products.

Additionally, they provide strong corrosion resistance by preventing moisture from reaching the surface. With thermal stability ranging from 71-300°C, they perform well in high-temperature environments.

These coatings are available in various colors and finishes so they are also good for aesthetic purposes.

Cons of Epoxy Coating

Despite their advantages, epoxy coatings require careful surface preparation, which increases production costs and time. They are also susceptible to UV rays, which can cause degradation.

The coating produces toxic fumes during application. It lacks flexibility so it is prone to cracking if the substrate moves or deforms.

Polyurethane Coating

Polyurethane coatings form when a polyol or polyamine reacts with an isocyanate. The result is a durable, flexible, and chemical-resistant layer protective layer.

Polyurethane coatings are quick-drying and can be applied to wood, metal, and painted surfaces.

How Polyurethane Coating Works

Before application, the surface must be cleaned, and a primer is often applied to improve adhesion. The polyol or polyamine is mixed with the isocyanate and then applied using a brush, roller, or spray equipment. The coating is then cured to harden.

Pros of Polyurethane Coatings

Polyurethane coatings provide excellent durability, with high abrasion, and chemical resistance. Their flexibility allows them to expand and contract with the substrate without cracking.

They also have superior resistance to UV exposure, unlike epoxy coatings. Available in multiple colors and finishes, polyurethane coatings enhance the appearance of coated surfaces.

Cons of Polyurethane Coatings

Over time, the surface layer may turn yellow. Additionally, polyurethane coatings do not absorb impact well, which limits their use in high-impact environments.

Polysiloxane Coating

Polysiloxane coatings are made of silicon-oxygen bonds. This coating forms successive layers of tight films that’s why it is highly resistant to environmental factors.

Polysiloxane coatings can be applied to steel, aluminum, galvanized metal, concrete, plastics, glass, wood, ceramics, and composite materials.

How Polysiloxane Coating Works

Before application, the surface is cleaned, and a primer is applied to improve adhesion. The base and curing agent are mixed and then applied using a brush, roller, or spray. The coating is then cured for a specific period.

Pros of Polysiloxane Coatings

Polysiloxane coatings offer excellent durability and protection against wear and corrosion. They are highly resistant to UV radiation, preventing fading or breakdown over time. This means that these coatings provide long-lasting protection against physical and environmental damage.

The coatings expand and contract with the substrate, reducing the risk of cracks or peeling. Additionally, they resist chemicals and remain stable at high temperatures, up to 300°C. Some formulations are environmentally friendly with low VOC emissions.

Cons of Polysiloxane Coatings

These coatings can become brittle over time and are typically more expensive than polyurethane coatings.

Zinc-Rich Coating

Zinc-rich coatings act as a sacrificial layer that absorbs oxygen before it reaches the substrate. Zinc coatings are primarily used to protect metals like steel, iron, and aluminum from rusting.

How Zinc-Rich Coatings Work

The surface is first cleaned and pretreated using methods like pickling, degreasing, or abrasive blasting. Zinc is then applied using hot-dip galvanizing, electroplating, or spraying. The coated part is allowed to cool before inspection.

Pros of Zinc-Rich Coatings

Zinc coatings are durable and offer excellent corrosion resistance by sacrificing themselves before the base metal corrodes.

They adhere well to various metals, maintain electrical conductivity, and can withstand temperatures up to 200°C. They are more economical than some alternatives like epoxy coatings.

Cons of Zinc-Rich Coatings

They are less effective at temperatures above 200°C and require periodic maintenance. Over time, the coating can develop a dull appearance.

Ceramic Coating

Ceramic coatings form a protective layer on a material’s surface, and they are commonly used in high-temperature and high-friction environments. Ceramic coatings adhere well to metals like steel, aluminum, and titanium. They are also compatible with plastics, glass, and composite materials.

How Ceramic Coatings Work

The application process typically involves thermal spraying, where ceramic powders are melted and sprayed onto the surface. Other methods include dip coating and spin coating, where the substrate is immersed or spun in a ceramic slurry before being dried and sintered.

Pros of Ceramic Coatings

Ceramic coatings can withstand extreme temperatures, often exceeding 1000°C. They provide excellent chemical resistance against acids, solvents, and alkalis.

The coating is highly durable, offering protection against scratches, oxidation, and corrosion. Additionally, ceramic coatings reduce friction and improve efficiency in moving parts.

Cons of Ceramic Coatings

These coatings can be brittle and may crack under stress. They require specialized equipment for application and can be expensive compared to other coatings.

Metallic Coating

Metallic coatings involve applying a layer of metal particles to a substrate. Metallic coatings are primarily used on steel, aluminum, and titanium surfaces.

How Metallic Coatings Work

There are two main application methods– thermal spraying and electroplating. In thermal spraying, metal powders are melted and sprayed onto the surface. In electroplating, a metal layer is deposited on the surface using an electric current.

Pros of Metallic Coatings

These coatings provide excellent corrosion resistance, especially in harsh environments. They offer high adhesion strength and ensure long-lasting protection.

They improve surface hardness and enhance reflectivity. Some metallic coatings also enhance electrical conductivity and wear resistance.

Cons of Metallic Coatings

They require regular maintenance, can be expensive, and may not work with all surfaces.

Acrylic Coatings

Acrylic coatings are protective layers made from acrylic resins. Acrylic coatings adhere well to concrete, metal, wood, and plastics.

How Acrylic Coatings Work

The surface is cleaned before applying the acrylic coating using a brush, roller, or spray. The coating dries quickly through evaporation, forming a protective film.

Pros of Acrylic Coatings

Acrylic coatings dry quickly so they are ideal for projects that require fast application. They provide good UV resistance, preventing fading and degradation from sunlight. These coatings are water-resistant, protecting surfaces from moisture and weather damage.

Acrylic coatings are also available in many colors and finishes, improving the appearance of coated surfaces.

Cons of Acrylic Coatings

Acrylic coatings have lower chemical resistance than epoxy or polyurethane coatings. they can also be less durable in high-abrasion environments.

Alkyd Coatings

Alkyd coatings are oil-based paints. These are one of the types of industrial paints that provide a durable and glossy finish but take longer to dry. Alkyd coatings adhere well to metal, wood, and masonry surfaces.

How Alkyd Coatings Work

Alkyd coatings are applied with a brush, roller, or spray. They dry through oxidation, meaning they react with air to form a tough, protective film.

Pros of Alkyd Coatings

Alkyd coatings provide strong adhesion so they are long-lasting on various surfaces. They are highly resistant to moisture so they are useful in humid or wet environments. These coatings also offer a smooth, glossy finish that enhances appearance and are cost-effective compared to other coatings.

Cons of Alkyd Coatings

They take longer to dry than acrylic coatings and release more VOCs so they are less environmentally friendly.

Polyvinyl Chloride (PVC) Coatings

PVC coatings are proactive layers made from polyvinyl chloride plastic. PVC coatings adhere well to metal, plastic, and concrete surfaces.

How PVC Coatings Work

The surface is first cleaned before the PVC coating is applied using dip coating, spray coating, or powder coating. The coating is then heated and cured to form a durable plastic layer.

Pros of PVC Coatings

PVC coatings provide excellent corrosion resistance, protecting metal from rust and moisture. They are also chemically resistant. They also offer good electrical insulation and increase the lifespan of coated materials.

Cons of PVC Coatings

They can become brittle over time, especially in extreme cold. PVC coatings also release harmful chemicals when burned.

Intumescent Coatings

Intumescent coatings are fire-resistant coatings. They form a thick, insulating layer that protects materials from fire damage. These coatings are applied to steel, wood, concrete, and other structural materials.

How Intumescent Coatings Work

The coating is applied in thin layers using a brush, roller, or spray. When exposed to high temperatures, the coating expands and forms a protective carbon layer, slowing the spread of fire.

Pros of Intumescent Coatings

Intumescent coatings increase fire resistance and protect structural materials from extreme heat. They are also durable and resistant to moisture, preventing degradation over time. They are also lightweight and easy to apply.

Cons of Intumescent Coatings

These coatings require regular maintenance and may degrade when exposed to harsh chemicals.

Factors to Consider When Choosing Industrial Coatings

Below are some important things to consider when choosing a coating for your project.

Type of Material

Each coating works best on certain materials. For example, metallic coatings are mostly used on metals, while epoxy coatings can be applied to metals, wood, and concrete. If you need corrosion resistance and UV protection, polyurethane coatings are a great option for metals, wood, and plastics.

Application Process

Some coatings are easier to apply than others. Consider how much time and effort the process will take. Some coatings require mixing and can be applied with rollers, sprays, or brushes. On the other hand, some coatings can be applied using hot-dip galvanizing which adds an extra step but provides strong corrosion protection.

Coste

Some coatings are cheaper but may not last long, while others are more expensive but provide better protection. For example, zinc coatings are cheaper than epoxy coatings, but epoxy may offer better durability in some applications. It’s best to find a balance between performance and cost.

Environmental Conditions

You should consider factors like weather, temperature, UV exposure, and chemicals. Some coatings perform better in harsh conditions. For example, if you need corrosion and UV resistance, polysiloxane coatings are a better choice than epoxy coatings because they can withstand sunlight and chemicals for a longer time.

Performance Requirements

If you need abrasion resistance, corrosion protection, or UV stability, you must choose a coating that offers those benefits. For example, epoxy coatings are not the best option for UV resistance– polysiloxane or polyurethane coatings would be better.

Uses of Industrial Coatings

Below is a list of common uses of each type of industrial coating.

Epoxy Coatings

• Automotive chassis and engine components
• Marine ship hulls and boat decks
• Aircraft wings and fuselage sections
• Circuit board coatings
• Interior and exterior surfaces of oil pipelines and storage tanks

Polyurethane Coatings

• Insulation and exterior light coverings for aerospace
• Seat cushions and bumpers in automotives
• Flooring and structural supports
• Aircraft protection
• Personal protective equipment

Polysiloxane Coatings

• Marine ship hulls
• Offshore oil platforms
• Bridges
• Paneles de carrocería
• Wind turbine blades
• Chemical storage tanks

Zinc-Rich Coatings

• Ship hulls
• Bridges
• Paneles de carrocería
• Transmission towers

Ceramic Coatings

• Gas turbines
• Boilers
• Componentes electrónicos
• Implantes médicos
• Equipos de procesado de alimentos
• Car paints

Metallic Coatings

• Power generation (gas turbines, boilers)
• Implantes médicos
• Piezas aeroespaciales
• Componentes de automoción

Acrylic Coatings

• Building exteriors
• Road markings
• Automotive finishes
• Maquinaria industrial

Alkyd Coatings

• Maquinaria industrial
• Ships
• Bridges
• Storage tanks
• Metal structures

PVC Coatings

• Pipes
• Wire insulation
• Fencing
• Roofing materials
• Storage tanks

Intumescent Coatings

• Commercial buildings
• Steel structures
• Industrial plants
• Oil refineries

Conclusión

Industrial coatings protect surfaces from damage, rust, and wear. Each type has its own strengths, so choosing the right one is important.

DEK offers high-quality coatings to help you protect your materials and extend their lifespan. Contact us today to find the best coating for your needs.