No matter how advanced or expensive a coating system is, it will fail if the surface underneath isn’t prepared correctly. In the coating industry, surface preparation accounts for up to 80% of coating performance — yet it’s the step most often neglected.
Here are the top five surface-prep mistakes and how to avoid them.
1. Skipping Thorough Cleaning and Degreasing
Coatings cannot bond to a surface contaminated with oils, dust, greases, salts, or grime.
When contaminants remain, adhesion fails — leading to peeling, bubbling, and early deterioration.
Solution:
Use industrial cleaning agents, degreasers, and pressure washing to ensure a completely clean substrate before any other preparation.
2. Using the Wrong Surface Profile
Different coatings require specific surface roughness levels to achieve proper adhesion.
For example, epoxies often need a deeper profile created through abrasive blasting.
Solution:
Follow SSPC/NACE (now AMPP) standards to match the surface profile to the coating system being used.
3. Ignoring Moisture and Drying Times
Moisture trapped in concrete or on metal surfaces is one of the most common causes of blistering and delamination.
Solution:
Test moisture levels, allow full drying time, and avoid coating during rain or high humidity.
4. Poor Environmental Control During Application
Temperature and humidity directly affect how coatings cure.
Too hot, and the coating skin-cures.
Too cold or humid, and it takes too long to dry — trapping solvents.
Solution:
Monitor ambient conditions and follow manufacturer specifications for application windows.
5. Selecting the Wrong Coating for the Substrate
Not all coatings are suitable for all environments.
Using the wrong system creates long-term failure even if prep was perfect.
Solution:
Choose coatings based on exposure conditions, substrate type, and performance requirements. When in doubt, consult professionals.
Final Thought
Surface preparation is the foundation of any durable coating system. Investing the time and expertise into correct prep ensures superior adhesion, longevity, and protection — saving you money and preventing premature asset failure.