How Industrial Coatings Prevent Corrosion

Corrosion isn’t just an inconvenience in chemical manufacturing; it’s one of the most expensive, recurring failures in the industry. 

According to NACE International, the global cost of corrosion exceeds $2.5 trillion annually, and the chemical sector represents one of the highest-risk contributors. Every leak, rust patch, or pitted weld isn’t just a maintenance issue…it’s a safety hazard, compliance risk, and a threat to profitability.

At Schmidt Industrial Services, we’ve seen how small corrosion issues can turn into large-scale operational losses. 

The ROI of proper industrial coatings is obvious: longer asset life, fewer shutdowns, reduced contamination risk, and reliable compliance. For chemical plants, this isn’t optional; it’s a matter of operational survival.

In this guide, we’ll break down how modern coating systems protect metal surfaces from corrosion and contamination, and how they directly impact food and chemical safety standards, production reliability, and total cost of ownership. 

Here’s what’s coming up:

• How industrial coatings and epoxy coatings form a protective barrier against corrosion and contamination.
• The real corrosion mechanisms inside plants (and why uncoated steel always loses).
• ROI-driven examples showing how coatings extend asset life and improve uptime.
• Key selection criteria for coating systems in food, chemical, and process environments.
• Lessons learned from 75+ years of coating and fabrication expertise at Schmidt Industrial Services

How Industrial Coatings Stop Corrosion Before It Starts

The principle behind industrial coatings is simple: isolate the metal surface from its environment.

But not all coatings are created equal, especially when it comes to the extreme demands of chemical processing. There are different types of industrial coatings, such as zinc-rich coats for corrosion resistance, epoxy systems for chemical protection, and polyurethane topcoats for durability and UV stability. Each of these types serves a specific role in protecting steel and other substrates.

Applying multiple coats in a system (starting with a zinc-rich primer, followed by an epoxy intermediate, and finished with a polyurethane topcoat) ensures optimal protection and extends the service life of the coated structure.

Barrier Protection

Epoxy-based coatings create an impermeable barrier that prevents moisture, oxygen, and chemicals from reaching the substrate, while specialized formulations boost their barrier strength even further.

This layer eliminates the electrochemical reaction that causes rust and metal loss. The choice of material in epoxies directly impacts their adhesion and durability, making them highly effective for long-term protection.

Chemical Resistance

High-performance epoxy coatings are formulated to resist harsh chemicals, including sulfuric acid, sodium hydroxide, and hydrogen chloride. In mixed-service facilities, multi-layer systems combine different coating chemistries (epoxy, polyurethane, fluoropolymer) to ensure comprehensive protection.

Thermal Resistance

Chemical plants frequently operate under high-temperature conditions.. A well-engineered coating must maintain adhesion and flexibility through thermal cycling, preventing cracking and delamination under stress.

Contamination Prevention

While corrosion is the most visible failure, contamination is the most dangerous.
Coatings that are non-porous and easy to clean prevent chemical cross-contamination and microbial buildup. This is a vital factor in both process and food safety, particularly in chocolate production, where plant environments must meet both industrial and sanitary standards.

Different Types of Corrosion Mechanisms

• Uniform Corrosion: Widespread oxidation across tank or piping surfaces, often from humidity or chemical vapors.
• Pitting Corrosion: Localized attacks that eat deep into metal, especially where surface coatings are weak or damaged.
• Crevice Corrosion: Hidden under gaskets or deposits, this form of corrosion thrives in stagnant areas where oxygen levels are low.
• Stress Corrosion Cracking (SCC): Caused by simultaneous exposure to tensile stress and corrosive chemicals, common in reactors and heat exchangers.

What’s at Stake

• Production Efficiency: Every corroded vessel or clogged line cuts throughput and drives up energy costs.
• Safety and Compliance: Corrosion can lead to leaks, chemical exposure, or contamination, triggering OSHA violations or shutdowns.
• Equipment Life Cycle: Replacing a 30,000-pound pressure vessel can cost millions. Preventive coating systems extend asset life by 5-10x.

Where Industrial Coatings Deliver the Biggest ROI

Storage Tanks and Pressure Vessels

From sulfuric acid containment to demineralized water storage, tanks are at the front line of corrosion exposure. Schmidt’s industrial coatings systems include multi-layer linings with high dielectric strength to resist permeation and blistering.

Piping and Transfer Systems

Internal pipe linings prevent under-deposit corrosion and chemical carryover, while external coatings protect against condensation and environmental humidity. Coated transfer lines last up to five times longer compared to uncoated carbon steel.

Heat Exchangers

As one of the most frequent and expensive maintenance issues, heat exchangers typically fail from internal corrosion or fouling. Protective linings minimize metal loss and help maintain heat transfer efficiency.

Secondary Containment and Flooring

Epoxy floor coatings and polymer linings prevent spills and leaks from seeping into subgrade concrete, reducing slip hazards and ensuring EPA compliance.

Food and Confectionery Process Areas

In chocolate production and other food environments, Schmidt’s McCarter division applies FDA-approved industrial coatings that meet sanitary and contamination prevention standards, ensuring both corrosion protection and compliance with food safety regulations.

Choosing the Right Coating System

Every plant has its own chemical profile, cleaning procedures, and process conditions. It is important to work with experienced contractors and a reliable partner to develop the right coating system for your specific needs.

Color selection is also important, as the right color can meet both functional and aesthetic requirements in industrial coatings.

1. Evaluate Exposure Conditions

First, identify what chemicals, pH levels, and temperatures your equipment faces. Even with ‘inert’ materials like water or steam can cause rapid oxidation when untreated.

2. Surface Preparation

Did you know that 75% of coating failures trace back to poor surface prep?

That’s why it’s essential to choose operators like Schmidt, who use abrasive blasting, degreasing, and profiling to meet SSPC-SP standards. This really is a critical step for adhesion and longevity.

3. Coating Type Selection

Depending on the application, there are some common coating types you’ll get to choose from:

• Epoxy Coatings: Excellent for immersion and chemical resistance.
• Polyurethane Coatings: Flexible and UV-resistant for outdoor or elevated temperature service.
• Fluoropolymer Coatings: Exceptional for high-purity or food-contact environments requiring non-stick performance.

4. Application & Curing

Next, proper mixing ratios, film thickness, and curing times will ensure the coating performs as intended. Schmidt’s certified applicators follow controlled procedures and document every stage for full traceability.

5. Inspection & Documentation

Compliance doesn’t end at application. Each project is accompanied by cure logs, adhesion tests, and thickness measurements for regulatory compliance and audit readiness.

The Schmidt Difference: Engineering Meets Experience

Schmidt Industrial Services brings over 75 years of expertise in industrial coatings, fabrication, and precision machining, all under one roof. Our integrated approach ensures coatings are part of a full lifecycle strategy, not an afterthought.

Consistently Providing Customers Quality:

• Coating Design: Custom systems engineered for your process chemistry.
• Fabrication Expertise: ASME U-Stamp and NBIC R-Stamp certified fabrication of vessels and components before coating application.
• Maintenance Integration: Seamless coordination with our machining and repair teams for minimal downtime.
• Regulatory Assurance: Every coating job is documented for safety, inspection, and audit compliance.

Engineered Resin Solutions (ERS)

When corrosion, leaks, or abrasion threaten your operation, Engineered Resin Solutions (ERS) steps in. As Schmidt’s dedicated coatings division, ERS delivers fast, durable protection for tanks, vessels, piping, and infrastructure across chemical, industrial, and food environments. Think of them as the tactical arm of Schmidt, quick to mobilize, meticulous in execution, and built for results that last.

Why ERS?

ERS goes beyond patchwork fixes; every project is engineered for lifecycle performance. Our proprietary coatings (like ERS 306 Metal Build and ERS 80RS Rust Stopper) protect against corrosion and chemical attack, while integrated support from Schmidt’s fabrication and machining teams allows for turnkey repair and coating under one roof.

Our coatings have protected assets in refineries, wastewater plants, educational facilities, and food production sites — all backed by one of the most complete warranties in the industry.

Pro Tips from the Coating Industry

With 75 years of experience under our belt, we know a thing or two about industrial coatings. Here are some practical tips learnt in the field:

• Never Recoat Over Active Corrosion: Coatings only adhere to properly prepared substrates.
• Schedule Maintenance During Planned Outages: Reactive repairs cost up to 4x more than preventive coating programs.
• Monitor Humidity and Dew Point: Environmental factors during application determine coating success.
• Invest in Documentation: Regulators look for traceability. Keep coating specs, batch certifications, and test results on file.
• Pair Coatings with Inspections: A well-coated tank still needs ultrasonic thickness testing to verify substrate integrity.

Looking for expert material guidance or custom polymer solutions? Our team is ready to help.
Contact us today to request a consultation or quote — and discover how Engineered Resin Solutions can support your next project from concept to completion.

FAQs

How do I know when it’s time to recoat my tanks or piping?

There’s no one-size-fits-all timeline. The right time to recoat depends on what your system handles. For example, if you’re running acids, chlorides, or caustics daily, coatings take a beating. 

The first signs of needing a recoat are subtle: a dull finish, minor blistering, or rough texture on the surface. If you can feel the metal grain when you wipe your hand across it, that’s a red flag. Once corrosion starts beneath the coating, it spreads fast. 

In all honesty, if you’re asking whether it’s time to recoat… it probably is. 

Are industrial coatings really worth the cost compared to stainless steel?

In many cases, yes, industrial coatings are really worth the cost compared to stainless steel. That’s because stainless steel has great corrosion resistance, but it’s not invincible. Acids, chlorides, and cleaning agents can still attack welds and seams over time. 

A properly applied epoxy coating or high-build lining system adds another layer of insurance, extending the life of your steel, protecting weld integrity, and saving you from full equipment replacement. 

What’s the biggest mistake plants make with industrial coatings?

The biggest mistake you can make with industrial coatings is skipping prep. If the substrate isn’t clean, profiled, and dry, even the best coating will fail. The other mistake? Treating coatings like paint. They’re engineered systems designed for a specific chemical environment. That’s why we test every surface, document every application, and match the coating to your exact process conditions. 

That’s how you prevent problems before they happen.

Protecting More Than Metal

Corrosion doesn’t announce itself; it creeps in quietly until a leak, failure, or recall makes it impossible to ignore. The right industrial coatings system isn’t just about aesthetics or durability; it’s about risk mitigation, contamination prevention, and long-term return on investment.

At Schmidt Industrial Services, we treat coatings as engineered solutions, not paint jobs. Whether you manage a chemical plant, a confectionery line, or a multi-process facility, our experts deliver coating systems that meet real-world challenges: high pressure, high temperature, high scrutiny. 

Because at the end of the day, coatings don’t just protect meta. They protect productivity, safety, and your bottom line.

We’re growing! Engineered Resin Solutions has expanded to Florida and the Southeast with a new Fort Lauderdale office and strategic hire. Read the full announcement on Business Wire.