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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.

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The application process requires careful surface preparation, which is absolutely crucial for coating success. This typically involves cleaning, degreasing, and sometimes mechanical or chemical treatments to ensure proper adhesion. Think of it like painting a wall at home – if you don't clean and prime the surface properly, even the best paint won't adhere correctly.

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Commercial coatings are selected based on several key factors:

• The substrate material (metal, concrete, wood, etc.)

• Environmental exposure conditions

• Required durability and lifespan

• Chemical resistance needs

• Cost considerations

• Environmental regulations

• Application method constraints

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The technology continues to evolve, with recent innovations focusing on developing more environmentally friendly formulations, improved durability, and smart coatings that can indicate wear or damage. For instance, some modern coatings incorporate self-healing properties or can change color to indicate when maintenance is needed.

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The impact of proper commercial coating extends far beyond appearance. It directly affects maintenance costs, equipment lifespan, safety compliance, and operational efficiency. For example, a well-chosen coating system on industrial equipment can prevent corrosion, reduce maintenance downtime, and extend the equipment's service life by many years.

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Quality control in commercial coating applications involves careful monitoring of environmental conditions (temperature, humidity), coating thickness measurements, and various tests to ensure proper adhesion and curing. This systematic approach helps ensure the coating will perform as intended throughout its expected service life.

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So as you can see, the “Coating Selection” is the most important aspect of your coating project. If you start with the wrong coating, you’re just never going to win the competition of guading and protecting your asset or substrate. 

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We use a decision making process. Asking a few questions. 

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1. What is the substrate?
2. What is the color?
3. What is the environment?
4. What has previously been installed?
5. What preparation is possible?
6. What is the service lifespan of the substrate?
7. Should the substrate be coated? 
8. Is the substrate going to require chemical or mechanical abrasion prior to coating?
9. What primer if any is necessary to bridge the substrate to the coating and the next coating.  Sometimes primer is not necessary, sometimes it’s absolutely necessary.