High-Performance Coatings: Enhancing Maintenance in Manufacturing Facilities

High-performance coatings are more than protective barriers. They provide an essential part of facility design, maintenance and operations. Selecting the right coatings presents an opportunity to align technical decision-making with strategic goals

In manufacturing environments, facility integrity directly impacts product quality, operational uptime and regulatory compliance. For engineers tasked with maintaining and upgrading these complex environments, coating technology plays a critical role in extending the lifecycle of infrastructure, preventing contamination and enabling efficient operations.

High-performance coatings are not just a short-term maintenance solution — they are a strategic investment (Figure 1). When selected and applied with precision, they support a wide range of engineering goals, such as reducing facility costs, ensuring compliance with industry regulations, improving environmental performance and adapting to evolving production demands.

 

The role of high-performance coatings

Coatings act as barriers that defend facilities against the wear and tear of daily operations. In high-throughput environments, like food and beverage, pharmaceutical, electric vehicle (EV) battery and automotive manufacturing facilities, that rely on aggressive cleaning agents, elevated temperatures and heavy machinery, coatings help preserve performance and safety while minimizing the need for repairs or shutdowns. Key benefits for facilities include the following.

Corrosion protection. Coatings prevent moisture and chemical infiltration that could compromise the structural integrity of tanks, piping and steel supports in facilities. For facility engineers working in regulated industries, this protection also supports compliance with regulatory standards related to facility safety and environmental controls.

Enhanced durability and flexibility. Coatings need to withstand not just mechanical wear, but also operational changes. Selecting systems that provide long-term durability while accommodating equipment adjustments or expansions can reduce downtime and redesign costs.

Improved safety. Slip-, chemical- and fire-resistant coatings can reduce exposure risks and contribute to overall workplace safety. These solutions are especially important in environments where compliance with OSHA and segment-specific safety standards is required.

Operational efficiency. Coatings that reduce maintenance demands and facility shutdowns can help maintain production throughput. For engineers managing lean teams or limited maintenance budgets, these incremental time savings can make a significant impact.

 

Engineering for coating selection

Engineers evaluating coatings must consider more than just the aesthetic properties — they need to assess how well those coatings align with facility goals and regulatory needs. Selecting the right high-performance coating system involves balancing durability, chemical resistance, sustainability and cost — all while ensuring the chosen product integrates with the larger design and operational strategy.

In many facilities, particularly those in the food-and-beverage and pharmaceutical segments, cleanability and slip resistance are often competing priorities. A surface that is easy to sanitize may be slick when wet, while a highly textured, slip-resistant surface can be harder to clean thoroughly. Engineers must work with safety and hygiene stakeholders to strike the right balance by selecting coatings that support both safety and sanitation without compromising compliance or operational efficiency. Key criteria when choosing coating systems might include the following.

Chemical resistance. In manufacturing environments, coatings must tolerate exposure to acids, solvents and sterilants. Choosing chemically resistant formulations prevents breakdowns that could lead to contamination, equipment failures or noncompliance.

Thermal resistance. Facilities like food-processing plants often cycle between hot and cold conditions. Coatings must be thermally stable and resist cracking or delamination from rapid temperature shifts – especially when applied to walls, ceilings and floors.

Cleanability and slip resistance. Engineers must weigh how the coating’s texture and finish affect both hygiene protocols and worker safety. The ideal solution balances ease of maintenance with traction to prevent slips and falls, particularly in wet or high-traffic zones.

Sustainability. More than ever, engineers want coatings that meet both performance and environmental goals, including minimizing exposure to volatile organic compouncs (VOCs). Low-VOC, water-based and energy-efficient coatings can support LEED certification efforts or corporate sustainability benchmarks while ensuring safety and durability.

Cost control. Coatings that last longer reduce the need for shutdowns and repairs, but upfront costs have to be weighed against total lifecycle value. Engineering teams often work with purchasing, maintenance and operations teams to ensure coatings meet technical and financial requirements.

Collaboration with stakeholders. Coating strategies should be developed in coordination with operations managers, environmental, health and safety (EHS) teams, contractors and suppliers. By aligning coating selection with project timelines, maintenance schedules and regulatory requirements, engineers can avoid costly redesigns and ensure smooth execution.

 

Surface preparation

Even the best coatings will fail without proper preparation. Surface preparation is where engineering precision has the greatest impact on long-term performance by providing a literal reliable foundation for coatings. Engineers must specify the appropriate cleaning, profiling and priming steps to ensure coatings adhere correctly and perform as expected. Two key standards help guide this process.

Association for Materials Protection and Performance (AMPP) Surface Preparation Standards. These outline methods for various substrates — from SSPC-SP-1 (solvent cleaning) to SSPC-SP-16 (brush-off blast cleaning of non-ferrous metals). AMPP standards apply to surfaces like steel and concrete, helping engineers match prep levels to coating system requirements and site conditions.

International Concrete Repair Institute (ICRI) Concrete Surface Profile (CSP) Guidelines. For concrete floors, ICRI rates surface roughness from CSP 1 (nearly smooth) to CSP 9 (very rough). These values ensure the profile aligns with manufacturer specifications — critical for flooring systems that rely on mechanical bonding.

Specifying the right surface preparation standard not only drives coating performance, but also affects project outcomes more broadly. Poor preparation can lead to premature failures, costly rework, wasted materials and delays, all of which increase resource consumption and undermine sustainability goals. By following AMPP and ICRI guidelines, engineers lay the groundwork for reliable, efficient and compliant coating applications.

 

Engineering for longevity

Coating systems aren’t entirely “set it and forget it” — even the highest-quality coating solutions benefit from routine monitoring and upkeep to ensure they continue performing as intended. Proactive and preventative maintenance strategies are essential in ensuring that coatings continue to protect manufacturing environments effectively.

Engineers play a pivotal role in striking the right balance between risk mitigation, cost control and operational continuity. While coatings are designed for durability, ignoring minor degradation can quickly escalate into significant issues that disrupt production and demand emergency repairs. There are a number of benefits that plants can experience when implementing an effective preventative maintenance program, including the following.

Minimized unplanned downtime. Early identification of coating failures — such as cracking, blistering or peeling — allows teams to address issues before they impact critical operations or violate safety standards.

Extended service life. Regular maintenance slows down the rate of degradation and helps preserve the coating’s protective properties, delaying the need for full recoat or repair.

Reduced lifecycle costs. Spot repairs and touch-ups are far more cost-effective than full-scale coating replacements. A proactive approach helps spread maintenance costs over time, easing budget strain.

Improved compliance. In highly regulated industry segments, such as pharmaceutical manufacturing, coating integrity is closely tied to facility safety, Current Good Manufacturing Practice (cGMP) compliance and audit-readiness. Proactive upkeep helps avoid costly fines, product recalls or certification delays.

Enhanced worker safety and extended equipment lifespan. Uneven, cracked or damaged flooring poses significant trip hazards for employees and can accelerate wear on forklift and automated guided vehicles (AGV) wheels.

Support ESG and sustainability goals. Extending the service life of a coating system reduces waste and lowers the environmental impact associated with recoating, surface preparation and disposal of failed materials.

 

Key strategies

There are a number of best practices that sites can include in their engineering and maintenance strategies to ensure future success. Several are outlined here.

Routine site surveys. Site surveys should be performed on a regular schedule — annually, semi-annually or quarterly, depending on the facility. These surveys should assess coating conditions across all critical surfaces, from floors and walls to structural steel, tanks and secondary containment. Roof areas should also be included in these inspections, as leaks can compromise both structural integrity and the performance of coatings and sensitive equipment.

• What to inspect: Look for signs of delamination, corrosion under the coating, discoloration, cracking, chalking and film thickness loss. Surfaces exposed to harsh chemicals or frequent thermal cycling should be prioritized
• Who should be involved: Engineers should collaborate with maintenance supervisors, EHS personnel and quality assurance teams to identify priority areas and align inspection protocols with industry-specific compliance needs

Data-driven reporting. Engineers should document findings using consistent inspection protocols and digital tools where possible. Coating condition data can then be used to forecast failures, plan phased repairs and justify capital investments in recoating projects.

Tailored repair schedules. Maintenance should not follow a “one-size-fits-all” approach. By analyzing wear patterns and exposures, engineers can develop zone-based repair schedules that address the most vulnerable areas first — whether that’s a high-traffic production corridor or sterile cleanroom. Roof sections prone to leakage should be prioritized in repair schedules to prevent damage to coated surfaces and support uninterrupted operations.

Use of compatible repair materials. Spot repairs must be done using materials compatible with the original coating system. Engineers should maintain documentation on coating specifications to ensure consistency in performance and regulatory compliance.

Coating lifecycle mapping. Creating a lifecycle map that aligns expected coating durability with production cycles, equipment upgrades and shutdown windows helps engineering teams make strategic decisions about when to repair, recoat or redesign. This long-view planning is essential in minimizing disruption and maximizing value.

 

Leveraging partnerships

Facility engineers don’t need to manage maintenance alone. Coating manufacturers and specialty contractors can be valuable partners in building and executing long-term maintenance plans. Engineers should take advantage of supplier support to help with the following tasks:

• Schedule onsite inspections or surveys
• Confirm recoat compatibility and surface prep requirements
• Train internal teams on early issue identification
• Develop facility-specific coating maintenance guides
• Stay updated on new materials or techniques that may reduce future maintenance demands

 

Segment-specific demands

Each manufacturing environment presents distinct operational challenges that coatings must overcome. Engineering teams play a critical role in aligning coating performance with facility-specific risks — whether driven by hygiene, chemical exposure, temperature fluctuation or regulatory requirements. Tailored solutions are essential to ensure long-term durability, compliance and efficiency.

Pharmaceutical facilities. In pharmaceutical manufacturing facilities, coatings are a critical part of maintaining controlled environments (Figure 2). Engineers must specify systems that align with cGMP and FDA requirements while supporting sterility, cleanability and durability.

• Cleanability and sterility: Coatings must create a smooth, non-porous barrier that resists microbial growth and holds up to aggressive sanitation protocols. Seamless finishes prevent contamination risks and simplify cleaning validation
• Chemical and abrasion resistance: Frequent exposure to sterilants requires coatings with exceptional resistance to chemical attack and physical wear
• Operational efficiency: Fast-curing, low-odor systems minimize downtime during installation or repair — critical for maintaining production schedules. Engineers should select systems that cure quickly without compromising performance
• Sustainable materials: Specifying water-based or 100% solids, low-VOC coatings that are free of red list chemicals supports LEED goals and sustainability initiatives while meeting cleanroom compatibility standards

Food-and-beverage processing plants. Coatings in food-and-beverage processing environments must balance hygiene, durability and worker safety, often under extreme and variable conditions (Figure 3). Engineers are responsible for ensuring materials can endure high-moisture, high-traffic and high-temperature fluctuations without failing.

• Moisture and thermal shock resistance: Daily washdowns, hot water exposure and chilling processes subject coatings to rapid temperature changes. Materials must remain intact and bonded to prevent water intrusion and delamination. Roof leaks can exacerbate these moisture challenges, introducing uncontrolled water into processing areas. Proactively identifying and repairing roof vulnerabilities is essential to maintaining hygienic conditions and protecting coating integrity
• Hygienic barrier performance. Seamless, crack-free coatings prevent microbial growth and support sanitation efforts. Systems should comply with FDA and USDA standards and be easily cleanable
• Worker safety. Textured, anti-slip surfaces help reduce slip-and-fall incidents, especially in wet or greasy areas. These finishes must meet OSHA safety standards without compromising cleanability
• Durability in harsh environments. Forklift traffic, impact from dropped tools and constant exposure to sterilants demand coatings that combine abrasion resistance with enough flexibility to resist cracking and peeling

EV battery facilities. From fire protection and chemical resistance to contamination control and static mitigation, coatings play a functional role in EV battery facility performance (Figure 4). When constructing an EV battery facility, the following coating-related considerations should be taken into account early in project planning:

• Cleanroom requirements: For cleanrooms, moisture vapor barriers and ESD-compliant resinous flooring should meet ISO 14644 cleanroom standards while supporting particulate control.
• Chemical resistance: Flooring in EV battery facilities must withstand harsh chemicals like N-methylpyrrolidone (NMP) and common spills in battery manufacturing.
• Electrostatic discharge (ESD): Static discharge can harm batteries and personnel. Floor coatings that are static dissipative or conductive and connected to grounded systems can help mitigate ESD risks.
• Workplace safety: Slip-resistant and impact-resistant surfaces in worker-heavy zones reduce injury risk and help ensure personnel safety.
• Durability for emerging technologies: Automatic guided vehicles (AGVs), autonomous mobile robots (AMRs) and robotic systems in EV plants create heavy wear zones, requiring impact-resistant coatings to endure traffic and prevent debris that could disrupt production.

Automotive manufacturing facilities. In automotive manufacturing, coatings play a vital role in supporting safety, operational efficiency and facility longevity (Figure 5). Engineers must navigate unique challenges ranging from oil-saturated surfaces to heavy equipment traffic, all while specifying systems that improve durability and minimize maintenance.

• Surface tolerance and preparation. Older facilities often have oil-saturated or poorly prepared concrete. Engineers must ensure substrates are properly prepped or select coatings tolerant to less-than-ideal surfaces
• Epoxy versus polished concrete. Polished concrete can stain, become slippery and lacks chemical resistance. Seamless epoxy or urethane systems offer better durability, traction and cleanability in these environments
• Traffic and equipment: Forklifts, AGVs and robotics wear down bare concrete. Robust coatings reduce surface damage, lower maintenance costs and extend floor life
• Slip resistance and safety: Washdown and fueling areas require non-slip systems to prevent accidents in wet or contaminated zones
• Paint shop requirements: Coatings used near painting operations must be free of silicones to avoid finish defects and contamination

By specifying performance-driven coatings tailored to each area of the facility, engineers can enhance safety, streamline maintenance and support long-term productivity in today’s increasingly automated automotive plants. ■

Edited by Mary Page Bailey

Acknowledgement

All images provided by the authors

 

Authors

Feraas Alameh (falameh@sherwin.com) is the market segment manager – Food & Beverage for Sherwin-Williams Protective & Marine. With 15 years in the coatings industry, he brings expertise in product development and market strategy. Alameh holds a bachelor’s degree from Cleveland State University and has completed executive education programs at Case Western Reserve and Ohio State universities.

Kristin Meyers (kristin.meyers@sherwin.com) is the market segment manager – EV Battery and Automotive Facilities for Sherwin-Williams Protective & Marine. She has nearly 20 years of experience in strategic marketing and business management, with a strong focus on the chemical and plastics sectors. Meyers holds a bachelor’s degree from Cleveland State University and has completed executive education programs at Case Western Reserve, John Carroll and Ohio State universities.

Michael Durbin (mike.c.durbin@sherwin.com) is the market segment manager – Pharmaceutical and Aerospace/Aviation at Sherwin-Williams Protective & Marine. A 38-year company veteran, he is an AMPP Senior Certified Coatings Inspector with Nuclear Facilities Certification (#8077) and a published author for NACE/SSPC. Durbin holds a bachelor’s degree from James Madison University.