Posted on November 29, 2024 by Brent Phillips

In industrial settings, the integrity of protective coatings is paramount for safeguarding structures and preventing environmental contamination. While primary coatings serve as the first line of defense, they are not infallible. This is where containment coatings step in, effectively addressing potential failures in primary coatings and providing a crucial second line of defense.

The Challenge of Primary Coating Failures

Primary coatings applied to concrete, steel, and other substrates in industrial environments face numerous challenges that can lead to failure. These include:

1. Substrate movement and thermal expansion
2. Chemical exposure
3. Mechanical stress
4. Environmental factors

Traditional coatings like epoxies, tars, and polyurethanes often lack the flexibility to withstand these stresses, resulting in cracks, holes, and compromised containment.

The Vital Role of Secondary Containment Coatings as a Backup System Secondary containment coatings are the backup system that prevents leaks and spills from reaching the environment if the primary coating fails. These coatings must possess specific properties to be effective:

1. Flexibility: The ability to accommodate substrate movement and thermal expansion
2. Chemical resistance: Withstanding exposure to various chemicals and contaminants
3. Durability: Resisting wear and tear from daily operations
4. Quick curing: Minimizing downtime during application and repairs

Advanced Polyurea Systems: A Promising Solution for Containment Coatings Recent advancements in coating technology have led to the development of flexible polyurea systems that address many of the shortcomings of traditional coatings. These advanced coatings offer several advantages:

1. Superior flexibility: Polyurea coatings can elongate up to 400%, allowing them to bridge cracks and flex with the substrate1.
2. Seamless application: Spray-applied polyurea creates a durable, waterproof barrier without seams or weak points1.
3. Rapid curing: Quick return to service minimizes operational disruptions1.
4. Versatility: Suitable for various substrates, including concrete, steel, and geotextiles1.

Application Considerations

Ensuring proper application is crucial for the effectiveness of any containment system that includes:

1. Thorough surface preparation
2. Adherence to manufacturer specifications
3. Consideration of environmental conditions during the application
4. Quality control measures

Failure to follow proper application procedures can lead to coating defects such as blistering, cracking, and delamination, compromising the containment system’s integrity.

Evaluating Coating Performance

Meanwhile, containment coatings offer solutions that prevent hazardous substances from leaking into the ground or escaping into the environment. Recent studies have shown that even intact blisters in coatings may not always provide adequate protection, and substrates beneath blisters may be more prone to pitting in specific exposures. Which only emphasizes the need for ongoing monitoring and maintenance of containment systems.

Routine and Regular Inspections Provide Proactive Protection

Containment coatings, particularly advanced polyurea systems, show great promise in addressing the potential failures of primary coatings. Their flexibility, durability, and rapid curing properties suit them for challenging industrial environments.

As coating technology evolves, further research and real-world performance data will be essential in refining containment coating solutions. By combining innovative materials with best practices in application and maintenance, industries can significantly enhance their ability to prevent environmental contamination and protect critical infrastructure.

Contact Cunningham Inc. to schedule your next coating inspection before problems arise. Call them at (620) 848-3030.