Optimizing Facility Management with High-Performance Coatings

Designing Durable Spaces

Manufacturing and production areas typically encompass large, open spaces that must be carefully designed and maintained.

The nature and utility of these environments demands robust flooring – in addition to wall and steel coating systems – that can withstand rigorous use while maintaining a high standard of safety and quality.

Flooring must be tailored to activities and traffic expected. For instance, areas exposed to foot traffic and rubber wheeled carts may require a moderate-duty, three-coat system (approximately 20-40 mils). However, areas subjected to heavy forklift traffic or other heavy machinery may need a heartier solution, such as a five-coat epoxy mortar system (approx. 250 mils) (Figure 2).

These considerations are also important when it comes to flooring systems for new or smooth concrete slabs, versus an existing, older eroded or pitted slab that may require resurfacing.

Additionally, flooring system topcoats must exhibit chemical resistance properties in manufacturing areas due to various chemicals and solvents that could spill during operations – qualities that reduce maintenance requirements and extend longevity.

Slip resistance is a key consideration. Floors must have the appropriate texture to prevent slips and falls, which account for a significant number of workplace injuries. In 2021, according to the Bureau of Labor Statistics, 18% of all nonfatal work injuries resulting in days away from work were from slips, trips and falls. As part of a company-wide safety program, flooring with suitable surface traction can help facility managers meet operational goals. The correct use of safety colors and floor marking provides visual cues to help prevent these accidents as well.

Light-reflective floor finishes can enhance the overall brightness of the area. The amplified room illumination can increase visibility, contributing to a safer work environment and improved production outcomes.

Walls and ceilings in manufacturing and production areas require special attention. Bright walls and ceilings create a well-lit environment, potentially reducing the need for additional lighting fixtures and improving energy efficiency. These coatings can also contribute to a cleaner and more professional appearance, which is important for areas frequently visited by customers or subject to audits.

Steel structures need protection against corrosion, which aids in structural integrity and longevity. Simply painting steel surfaces is often insufficient for the harsh conditions often found in manufacturing and production environments. Advanced protective coatings are therefore required to sufficiently shield steel from the corrosive effects of moisture, chemicals and other factors.

Maintaining manufacturing and production areas is a complex task for facility managers. A comprehensive strategy for proactive maintenance is essential, including setting inspection schedules, recognizing signs of wear, implementing preventive measures, and preparing ready-to-go repair strategies to quickly address any surface issues.

The number of choices can be daunting, but experienced coatings specialists can provide valuable support, allowing managers to focus on other critical operations.

Wet and Dry Considerations

Wet and dry processing areas – especially in the food and beverage industry – present unique challenges.

Due to their distinct operational requirements and conditions, these areas require specific maintenance and protective measures to maintain the integrity of processes, the safety of the products and compliance with health regulations.

In dry processing areas, controlling temperature and humidity promotes the proper handling and processing of food products. The flooring systems in these areas must be impervious to moisture to prevent contamination and remain durable. Resinous flooring systems are ideal for these environments as they provide a seamless, non-porous surface that resists moisture infiltration and maintains integrity, even at varying temperatures. These systems also offer the necessary hardness and strength to withstand mechanical stresses and the high temperatures typical of dry processing.

On the other hand, wet processing areas frequently use water for processing – which requires flooring systems to be highly resistant to constant moisture exposure and aggressive cleaning protocols (Figure 3). Wet environments benefit from resinous flooring systems with textured finishes that enhance slip resistance, reducing the risk of slips and falls. The flooring in wet areas must also be impervious to cleaning agents, process-related chemicals and other liquids to help support long-term performance and minimized maintenance needs.

Walls in both wet and dry processing areas require advanced protective coatings that can withstand the unique challenges of each environment. In dry processing areas, wall coatings must prevent moisture infiltration while providing a durable surface that can resist common impacts and abrasions. These coatings also help maintain a hygienic environment by preventing the buildup of contaminants and allowing for easy cleaning.

In wet processing areas, wall coatings need to be even more resilient. They must endure constant moisture, aggressive cleaning procedures and chemical exposure. Advanced protective coatings allow walls to be properly and efficiently sanitized for food safety. These coatings can also help prevent the growth of mold and mildew – a significant concern in consistently damp environments.

Steel surfaces in processing areas are also susceptible to damage from moisture and chemicals. In dry processing areas, steel components need coatings that can withstand temperature variations and resist corrosion. Protective coatings provide a barrier against environmental factors that could compromise the structural integrity of these elements.

In wet processing environments, the challenge is even greater. Steel surfaces must be protected from regular water exposure and chemical agents used in processing and cleaning. Advanced anti-corrosion coatings are essential to prevent rust and degradation.

Figure 1. High-performance coatings applied strategically to floors, walls and steel structures in manufacturing and production areas can help mitigate wear and tear, reduce maintenance costs, extend facility asset lifecycles, support regulatory compliance and promote safer, more efficient working environments.

Figure 3. Wet processing areas require flooring systems that are highly resistant to constant moisture exposure and aggressive cleaning protocols. Such systems often feature textured finishes to enhance slip resistance and reduce the risk of slips and falls.

Safety & Sterility in R&D

Research and development (R&D) laboratories and cleanrooms are critical environments where the highest standards of cleanliness, sterility and environmental control are a central focus. The right coatings – carefully selected and applied – help safeguard these environments, protecting both the integrity of these spaces and the valuable work conducted within them.

Resinous flooring systems are ideal for such settings due to their seamless nature, eliminating joints or cracks where contaminants can accumulate. These floors provide non-porous surfaces that can withstand the rigorous cleaning and sanitizing procedures necessary to help control a sterile environment. The durability of resinous flooring also means these systems can handle heavy traffic.

Flooring in many types of cleanrooms requires electrostatic dissipative (ESD) properties to prevent static discharge, which can damage sensitive electronic components, disrupt experiments and injure workers.

Walls and ceiling coatings need to be smooth, durable, and resistant to chemicals and frequent cleaning. Protective wall and ceiling coatings create a long-lasting hygienic barrier that is easy to sanitize, preventing the buildup of dust, bacteria and other contaminants.

For cleanrooms, it is necessary to have seamless transitions from floor to wall to ceiling to minimize potential points of contamination. Seamless integrations, including cove bases, allow the entire space to be effectively cleaned and sanitized, maintaining the required sterility (Figure 4).

Safety in R&D laboratories and cleanrooms extends beyond contamination control to include fire safety. These systems involve the application of fire-resistant coatings to structural elements, helping to prevent the spread of fire and protect the overall integrity of the building. Proper fireproofing enhances the safety of personnel and equipment, reducing the risk of catastrophic damage.

While traditional commercial paint and coatings are ideal for many environments, they are generally not suitable for R&D laboratories and cleanrooms due to their lack of durability and resistance to the demanding conditions of these environments. These traditional light-duty solutions are also more likely to require frequent repairs and replacements, which can disrupt operations and compromise the integrity of the cleanroom.

Advanced industrial grade protective coatings provide the longevity and resilience required to maintain a sterile, safe and compliant environment.

Figure 4. Adding an integral cove base where flooring interfaces with a vertical surface provides a seamless transition that helps direct water and cleaning agents toward floor drains, minimizing standing water and bacteria harborage points.

Figure 5. Heavy-duty industrial grade flooring is needed in warehousing, storage and shipping areas to help protect concrete substrates from potential damage inflicted by heavy moving equipment, high traffic, abrasion and impact.