A high-quality paint job protects commercial spaces and extends their lifespan. It also helps reduce costs while maintaining the aesthetics of retail stores and other establishments. However, if coatings fail, the results can be costly for the business.
Peeling, blistering, or cracking paint makes spaces look worn out and exposes surfaces to moisture, corrosion, and structural damage. Many of these issues arise from preventable mistakes such as poor surface preparation, improper application techniques, or environmental factors overlooked during installation.
Fortunately, these failures can be avoided with the right expertise and application methods. Below, we’ll explore the most common causes of coating failures in commercial painting. You’ll learn practical tips on coating failure prevention and ensure your coatings last as long as possible.
What Are the Most Common Causes of Coating Failures in Commercial and Industrial Spaces?
Coating failures in commercial and industrial buildings can lead to significant damage, increased maintenance costs, and a reduced lifespan of painted surfaces. These failures often stem from key issues that can be prevented with proper planning and execution.
Some of the most common causes of coating failures include the following:
1. Poor Surface Preparation
If surfaces are not cleaned and prepared correctly, coatings may not adhere properly. Dust, rust, grease, or old paint residues can prevent proper bonding, leading to peeling and other issues. Surface preparation methods such as abrasive blasting, chemical cleaning, or power washing are essential to create a strong foundation for coatings.
2. Extreme Weather Conditions During Application
Temperature and humidity levels significantly affect coating performance. If applied in very hot, cold, or humid conditions, coatings may dry too fast, too slow, or unevenly. This can lead to cracking, bubbling, or poor adhesion. Following manufacturer guidelines on temperature and humidity is crucial for achieving durable coatings.
3. Surface Contamination
Even minor contaminants like dust, oil, or grease can cause coating failures. These contaminants cause bubbling, peeling, or flaking over time. Ensuring surfaces are thoroughly cleaned before application with degreasers, solvent wipes, or proper sanding techniques can help mitigate these risks.
4. Incorrect Coating Thickness
Applying a coating too thin may result in premature wear and insufficient protection while applying it too thick can lead to cracking or improper curing. The correct thickness should always align with manufacturer recommendations and be measured with a dry film thickness gauge to ensure even application.
5. Improper Drying or Curing Times
If coatings do not dry or cure properly, they may remain soft, leading to reduced durability issues. Rushing the process by applying multiple coats too quickly can trap solvents and weaken the coating. Controlling drying conditions, including ventilation, humidity, and temperature, ensures a strong and long-lasting coating.
6. Incorrect Application Techniques
The method of application significantly affects coating performance. Uneven application, overbrushing, or incorrect spray techniques can lead to streaking, poor adhesion, or excessive film buildup. Using the right tools and following manufacturer recommendations ensures a smooth, durable finish.
7. Coating Formulation Issues
Not all coatings are suitable for every surface. Choosing a formulation that lacks the necessary resistance to chemicals, UV exposure, or abrasion can lead to rapid failure. Ensuring the coating matches the environmental demands of the space prevents premature wear and increases paint longevity. For instance, elastomeric flooring is a good fit for gyms, fitness centers, and commercial establishments that require better slip resistance and impact absorption.
How Does Poor Surface Preparation Lead to Coating Failures, and How Can It Be Prevented?
One of the biggest reasons coatings fail is improper surface preparation. If a surface is not cleaned and prepped correctly, the coating may not adhere properly. This can lead to peeling, blistering, or flaking over time.
Surface preparation includes removing dirt, grease, oil, and other contaminants from surfaces that will be painted on. This can be done through power washing, abrasive blasting, or chemical treatments. The preparation method depends on the surface type.
Ensuring the surface is dry and free from loose particles before applying the coating is essential for proper paint adhesion. Neglecting preparation steps can result in the coating breaking down much sooner than expected.
How Does Humidity and Temperature Affect the Adhesion of Coatings?
Environmental conditions, especially humidity and temperature, play a major role in how well coatings adhere to a surface. If the conditions aren’t right, the coating may not bond properly.
High humidity causes condensation on surfaces, preventing coatings from sticking properly. Ideally, relative humidity levels should be between 20% and 60% during application, depending on the coating type.
Humidity levels can have a terrible impact on different coatings. For instance, too much moisture on epoxy coatings can cause amine blush, affecting adhesion and durability. Excess humidity can lead to bubbling and improper curing on polyurethane coatings, slowing down drying times for acrylic coatings.
Maintaining humidity levels ensures coatings cure properly and provide long-lasting protection. If humidity is too high, coatings may not adhere properly; if too low, the coating may dry too fast and become brittle.
To maintain proper humidity levels:
- Use dehumidifiers or air conditioning in enclosed spaces to reduce excess moisture.
- Increase ventilation by using fans or exhaust systems to circulate air and remove trapped humidity.
- Monitor humidity levels with a hygrometer before and during the application process to ensure they remain within the recommended range.
- Avoid painting during peak humidity hours, such as early mornings or late evenings, when condensation is more likely to form on surfaces.
What Are the Consequences of Applying Coatings in Adverse Weather Conditions?
Applying coatings in poor weather conditions can lead to several issues, like blistering and an uneven finish. If coatings are applied in extreme heat, they can dry too quickly, preventing proper bonding. In cold weather, coatings may not dry at all, leading to longer curing times.
Wind and rain also play a role in coating failures. Strong winds can bring dust and debris into the paint, while rain can wash away uncured coatings. Choose the right weather conditions and use protective barriers during application, such as tarps or enclosures, to shield surfaces from wind and rain.
In addition, scheduling painting projects during optimal weather windows and using fast-drying coatings when necessary can help. You can also use heated or ventilated enclosures in extreme temperatures to mitigate weather-related challenges.
How Can Contamination of the Surface Lead to Coating Failure?
A contaminated surface can be one of the biggest challenges to a successful coating application. Even small amounts of dust, oil, or grease can prevent proper adhesion, leading to bubbling, peeling, or flaking over time.
To prevent this from happening, all surfaces must be thoroughly cleaned before application. This includes degreasing, sanding, or using specialized cleaning solutions to remove any foreign particles. In high-traffic commercial and industrial areas, ongoing maintenance is necessary to ensure that contaminants do not compromise the integrity of the coating.
What Role Does Coating Thickness Play in Its Performance and Durability?
Applying the correct thickness ensures that a coating performs well and lasts as long as expected. If the coating is too thin, it may wear out quickly, exposing the surface to environmental damage. If it’s too thick, it can lead to cracking and improper curing.
It is best to follow manufacturer recommendations on coating thickness and use proper application techniques, such as spray, roller, or brush methods. Thickness should also be measured and monitored using tools like a wet film thickness gauge to ensure even application across all surfaces.
How Do Coating Failures Differ Between Interior and Exterior Applications in Commercial Properties?
The conditions affecting coatings vary between interior and exterior surfaces. Interior coatings are generally protected from extreme weather conditions but can still suffer from poor ventilation, moisture buildup, and contamination from cleaning chemicals. Exterior coatings, on the other hand, are exposed to direct sunlight, temperature changes, and moisture.
Can Coating Failures Be Attributed to Improper Curing or Drying Times, and How Can This Be Avoided?
If coatings do not dry or cure properly, they may remain soft and easily worn out. To avoid this, it’s important to follow drying and curing time recommendations provided by the manufacturer.
What Are the Best Practices for Choosing the Right Coating for Specific Industrial Environments?
Some coatings are designed to withstand high temperatures, while others provide resistance against chemicals, moisture, or abrasion. It is important to match the coating type to the needs of the space. For example, areas exposed to heavy foot traffic require durable, high-performance coatings, while industrial spaces with frequent chemical exposure need coatings with strong chemical resistance. Consulting with a professional painting contractor can ensure the best coating is chosen for each situation.
The Value of Expert Coating Services
Many coating failures can be prevented by understanding their causes and taking the right precautions. Choosing the right coating and following best practices for application can help ensure long-lasting results.
With over 40 years of experience, Raider Painting has been a trusted provider of high-quality commercial and industrial coating solutions. Our expert team understands the challenges of coating applications and offers tailored solutions to prevent failures and extend the life of your coatings. Contact us today to learn more about coating failure repair and how we can protect and enhance your commercial property.
