Protective coatings are the first line of defense against corrosion of water and wastewater lines, primary and secondary containment vessels, metallic pipes, and much more. But how do you ensure that a protective coating will be properly applied?

One obvious answer might be something like, “Make sure the surface is properly prepared, that the coating material is protected against contamination, and that it is applied evenly and at the right temperature, sheathing (if any) should be smooth and free of pinholes, bubbles, etc.” and so on, through a long list of application and testing procedures.

These points are all essential, of course. But there is another point which, though often overlooked, is just as important: communication.

The View from the Field

I recently attended several coating application classes, to see exactly how applicators are being instructed in the details of their craft and how the process looks from the applicator’s point of view, which is very different from that of the corrosion consultant, the design engineer, of even the project manager.

The experience drove home the fact that the success of a coating job depends heavily upon successful communication between the engineer and the contractor on one hand, and the individuals or team who will handle and apply the coating materials on the other. In particular, the engineer must make sure the applicator understands and is capable of responsibly addressing five issues:

1. Changes in the industry. Coating formulations have been evolving in order to comply with changed environmental regulations and in response to issues such as volatile organic compounds (VOC) restrictions and lead paint disposal on industrial coating applications. The need to change coating formulation has opened up a new competitive market for the industrial coating industry. New epoxy and polyurethane coatings with short pot lives warrant the use of plural component application equipment. This method of application has increased applicator productivity as well as decreased labor costs. The design engineer should be aware of current application practices and include the necessary certification(s) in the specifications in order to qualify an applicator for a particular job.

2. Lessons learned.” With the use of new coating systems, new application procedures must be followed in order to achieve a high-quality finished product. Experience from the field makes it possible to eliminate or at least minimize the likelihood of coating failure by revising and/or clarifying the coating specifications—for example, by including very specific guidance: specific handling, storage and loading requirements, requiring a saw cut at coating termination points to create a mechanical bond between coating and the substrate, and so on.

3. Surface preparation. Communication is always a two-way street. The engineer must be careful to educate himself or herself about the practical techniques of surface preparation. In particular, before completing the specifications for a coating project, It is essential for the engineer to understand the contractor’s capabilities, and to know what method(s) of surface preparation the contractor prefers, and why. This is one of the most obvious points where better communication could help save time and money for both the contractor and the client.

4. Problem areas. In any coating job there is a chance of problem areas. When a problem arises during the application of a coating, it may be a good idea to contact the coating manufacturer’s representative. If the problem is one they have encountered before, they may have some suggestions that can help you and your applicator resolve the problem quickly.

5. Quality inspection. Careful inspection is an essential part of a successful project, including inspection of surface preparation, coating application and application methods, pinhole and holiday detection. Engineer and contractor should discuss and agree upon the best type of inspection for the job—whether destructive or non-destructive methods will be used, what types of equipment are required, and so on. This should be done before work begins, so the contractor can be prepared with the proper equipment, personnel, and schedule.

Plan for Success

To make sure all parties have the same expectations with regard to the project objectives and how they will be achieved, at least one “up-front” pre-construction meeting should be scheduled where all relevant issues can be identified and resolved. This will help the contractor plan for the job and aid the applicator team in achieving a quality protective coating.