Commercial Coating Guide

Commercial coating refers to the application of specialized protective and decorative finishes to surfaces in commercial and industrial settings. These coatings serve multiple critical functions beyond mere aesthetics, acting as barriers against environmental factors, chemicals, moisture, and physical wear.

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At Moorhouse Coating, we have many factors to consider when selecting a protective coating.  Where is the substrate located?  And what the heck is a "Substrate"?

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Let me explain what a substrate is in the context of coatings.

A substrate is the base material or surface onto which a coating is applied. Think of it as the foundation or underlying layer that supports the coating system. 

Just as a canvas provides the base for an artist's paint, the substrate provides the base for industrial or commercial coatings.  In the example of a painter's canvas.  It is the canvas itself that is considered the "substrate".

To understand this better, consider how different substrates interact with coatings. Steel, for example, has different surface characteristics and coating requirements than concrete. Each substrate material has unique properties that affect how well a coating will adhere and perform. The substrate's porosity, surface tension, chemical composition, and even its temperature can all influence the coating process.

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Common substrate materials in coating applications include:

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Metals (steel, aluminum, copper)

Concrete and masonry

Stucco, Brick, 

Wood and wood products

Plastics and composites

Glass

Ceramics

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The relationship between substrate and coating is crucial because the substrate's condition directly impacts coating success. Surface preparation of the substrate is particularly important. For instance, if you're coating steel, any rust, oil, or contamination on the substrate surface can prevent proper coating adhesion, leading to premature failure.

The substrate also influences coating selection. Different substrates require different types of coatings, primers, or surface treatments. For example, a coating that works perfectly on aluminum might fail completely on concrete because these substrates have different chemical properties and physical characteristics.

Think of the substrate-coating relationship like building a house: the substrate is the foundation, and the coating is the protective outer layer. Just as a house needs a solid foundation to remain stable, a coating needs a properly prepared substrate to perform its protective function effectively.

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The science behind commercial coatings involves complex polymer chemistry. Most commercial coatings consist of three main components: a resin system (the binder that forms the coating film), pigments (for color and additional protection), and solvents or carriers (which evaporate during the curing process). Additional components like additives and hardeners may be included to enhance specific properties.

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Common types of commercial coatings include:

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Epoxy coatings are particularly valuable in industrial settings due to their exceptional durability and chemical resistance. They form through a chemical reaction between an epoxy resin and a hardener, creating an extremely tough surface that can withstand heavy foot traffic and chemical exposure. You'll often see these on factory floors or in commercial kitchens.

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Polyurethane coatings offer excellent weather resistance and color retention. Think of them as a protective shield that maintains its appearance even under harsh sunlight and varying weather conditions. They're frequently used on exterior surfaces of commercial buildings and outdoor equipment.

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Powder coatings represent an environmentally friendly option that's become increasingly popular. Unlike liquid coatings, powder coatings contain no solvents and are applied electrostatically as a dry powder before being heated to form a "skin." This process creates virtually no volatile organic compounds (VOCs) and provides excellent coverage with minimal waste.