Improve Asset Reliability With Industrial Coatings

epoxy flooring for asset reliability

Finishes are often overlooked from the Asset Reliability Manager’s perspective.  But if you learn the many benefits of industrial and commercial coatings, you can see how they can improve some of the most important assets in any facility.

When a company or facility thinks of their assets, their first thought is typically production machinery.  Which makes sense.  It gets used daily, to produce the product that the company is selling.  And if that machinery goes down, then that product is no longer being produced.  There’s not a lot of degrees of separation between the machinery and money.

Which is why it’s perplexing that so many facilities overlook a vital component to sustaining their productivity: their facility.

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Commercial Painting Problems & Solutions – When Paint Peels From Brick

paint peeling from brick

Brick is a challenging surface to paint.  But its grooves and valleys are the least of any applicator’s concerns.  Because the real distressor lies within the mortar.

Here are The Problems That Can Happen When Painting Commercial or Industrial Masonry

Masonry and block walls are held together with mortar mixes.  These mortar mixes offer excellent adhesion and compression strength, which allows the structure to maintain its integrity.  However, these mortar mixes are also made from many soluble salts.  And when these material get wet, moisture wicks the salt water to the exterior of the brick and mortar joint.  When the water evaporates, the brick substrate is left with a layer of sodium film, which prevents the paint from adequately adhering to the substrate, causing it to peel and disbond.

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Commercial Paint Problems & Solutions – Painting Galvanized Steel

failed paint on galvanized steel

Galvanized steel has exceptional benefits for any plant or facility.  It is durable and can tolerate high moisture, due to the zinc it’s boiled in.  However, although versatile, it is a challenge to coat due to the oil residue that protects the substrate.

Here’s how Commercial Painters Avoid Paint Peeling From Galvanized Surfaces

Galvanized steel is frequently used in many commercial and residential settings.  It’s used for gutters, down spouts, corrugated decking, and many other common applications.  Although it is tolerant to weather, due to its zinc coating, it is very challenging to paint.

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Commercial Paint Problems & Solutions – Excessive Chalking

paint failures chalking

Whether you’re dealing with commercial painting or residential painting.  Chalking is a frequent problem that occurs in the aging paint field.  What’s worst is that by the time it occurs, you need to increase the amount of prep required for the job.  So here’s how and why you need to be proactive before chalking occurs.

Here’s How Paint Begins To Chalk

You can take all the time in the world to meticulously apply and brush a flawless coat of paint.  But no matter how careful and tedious you are, your coating will eventually break down.   There are many elements that can break down a coating.  But the most hazardous are ultra violet rays.

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Commercial Painting Problems & Solutions – Cracking

cracking paint problems

Commercial Painting comes with its inherent challenges.  And if not applied correctly, those challenges can present themselves in unflattering ways.

Here’s how paint becomes victim to cracking and flaking:

When studying the problems, you’ll notice that the cracking occurs through the entire film of paint, all the way to the substrate.  This is a common problem when underlying coats of paint are applied to existing coats that have not been adequately prepped.

The underlying coats lose their elasticity.  Which means that they can’t bend and flex with the substrate when it expands and contracts during varying temperature changes.  So as the substrate swells and compresses, the aged coating begins to delaminate and shingle.

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Commercial Painting Problems & Solutions: Blistering

commercial painting companies

Despite its benefits, Commercial Painting can come with a world of problems.  And one of the most common is blistering.

You’re probably working outside.  And the sun is probably beating down on you and the substrate.  But you’re painting away, minding your work, making sure there’s an even spread of material over the substrate, making sure there are no roll marks or brush marks.  and keeping a close eye on your wet edge.

But aside from your astute attention to detail, you begin to notice something a few hours after you’ve painted.  The thin film begins to bubble and create blisters.

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Commercial Painting Problems and Solutions: Alligatoring

alligatoring paint problems

Despite its benefits, Commercial Painting can come with a world of problems.  And one of the most common is Alligatoring.

Sure, painting can come off as a fairly simple part of the construction project.  But just like anything, after you consider the varying environmental conditions, the varying products, and the plethora of application methods, you can quickly understand how the painting trade requires skill and experience.

And if you’ve seen a “finished” paint surface that looks like the image above, you’ll know that the “painter” is lacking in skill and experience.

This paint problem is called alligatoring.  We’ve discussed it before, but like to regurgitate topics so that everyone is always fresh on the basics of commercial coating application.

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Installing Epoxy Floors in the Cold – PennCoat

epoxy on cold concrete

Epoxy floors are great.  But they can prove challenging in cold areas.

Installing epoxy floors are inherently difficult.   Between getting ratios correct, to thoroughly mixing resins and hardeners, and ensuring that there’s an equal amount of aggregate distributed throughout the material are just a few of the problems that could arise.

But beyond the material, there are issues that can arise from the concrete that’s receiving the coating.  And one of the most common issues is concrete temperature.

Temperature can play an important role in the success of an epoxy installation.  The general rule of thumb is don’t go against the tech data sheet.  Most tech data sheets will vary in temperature.  However, if the TDS isn’t readily available, then 50° F is the most consistent number across the board.

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Common PPE’s for Facility Painting & Epoxy Flooring

Industrial Safety Team
penncoat safety team

Personal Protection Equipment (PPE’s) is one of the most important pieces of equipment that should be at every job site.  It offers salubrious benefits, and helps maintain everyone’s safety.  Different jobs require different PPE’s.  Here’s a run-down of the most commonly used PPE’s for all of our commercial painting, industrial painting, and epoxy flooring projects:

  • Bump Cap/Hard Hat –
    • Our job environments don’t always require bump caps or hard hats.  When working in office areas, or clean rooms, or warehouses, it’s uncommon to require hard hats.  The facility doesn’t request them in their required PPE’s, and the area doesn’t pose a threat that would require the need for a bump cap.  But every once and a while, we do get placed in industrial, construction zones that require hard hats.  When cranes, and loose debris are being constructed, hard hats are important.  Additionally, if painting a facility’s ceiling, and there are pipes and I-beams, and other obstructions, then it is often required by the facility, and our own Project Manager to ensure the crew is wearing a bump cap.
    Eye Protection –
    • Eye protection is always required.  Whether we are only painting bollards, or if we’re grinding an entire slab, eye protection is always required.  An eye is too sensitive to flying debris, and should be protected at all times.  But glasses aren’t enough.  Safety glasses need side shields, so that flying obstructions can’t come in contact from the side.  So regardless of what type of work you’re conducting, proper safety glasses are required.
    Hearing protection –
    • For the most part, ear protection is required only in manufacturing facilities.  Their loud equipment and machinery increase the decibels beyond a safe threshold for an unprotected human ear.  So in all manufacturing areas, hearing protection is required.  This is not the same for warehouses and office environments.  However, regardless of the area, we do require our installers to wear hearing protection during specific operations.  If someone is power washing, blasting, spraying, hand grinding, or working a walk-behind grinder, then we mandate that installers are to wear hearing protection.  Ear plugs are the most common form of hearing protection for commercial and industrial painting.  But sometimes, when we have to blast areas, the ear muffs are required.
    Hand Protection
    • When dealing with paints and epoxies, cotton gloves typically serve the best.  They are relatively versatile, and can handle a lot of flexibility.  They absorb enough paint and epoxy so that your hands can stay reasonably clean.  But when using mineral spirits or denatured alcohol, we request our installers to use coated cotton gloves.  The coated gloves help protect the installers.  Many solvents can be exposed through the skin, which can have an adverse affect on your health and safety.  But when grinding, the installers are required to wear tear-proof gloves, to ensure their protection from high-speed grinders.
    Feet Protection
    • The most common foot protection is leather, steel-toed boots with meta guards.  When dealing with epoxy flooring and facility painting, there are many heavy pieces of equipment and material that could cause damage if striking your foot.  Although this may seem like a common PPE requirement, some facilities only require leather boots.  Even if the facility only calls for leather boots, most installers will still wear their steel-toed boots, due to the nature of the heavy equipment and material frequently used on epoxy flooring jobs, and commercial painting jobs.

    These are some of the most common PPE’s for each job.  However, there are more safety concerns that a  Project Estimator needs to consider when looking at potential work including fork-lift traffic, fall protection, hot pipes, or anything else that needs to be considered to ensure someone’s safety.

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Textured Floors For Increased Safety – PennCoat Epoxy Floors


Decreasing Facility Hazards with Epoxy Flooring

We were contacted by a facility about increasing the slip-resistance around their dock doors.  Currently, whenever the dock floors get cold and wet, they get to be very slippery, causing fork-lifts to slip and slide.  And an out-of-control fork-lift is a huge safety concern.

epoxy flooring maryland

So our solution was to increase the floor’s slip-resistance.   But achieving this isn’t as simple as laying textured tape onto the floor.  When dealing with fork lifts, you have to consider the weight of the machines, and also that these fork lifts are dragging skids across the floor.  That’s a lot of pressure and tension being exposed to the floor.  So it’s important to find an epoxy coating that can tolerate this type of environment.

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