Frequently Asked Questions
What plant engineers and maintenance planners ask before approving the work.
Overcoating Existing Corrosion
Can you really coat over rust that is already there?
Over sound, tightly-adhered rust — the kind you cannot lift with a putty knife — yes. The membrane cuts off the water and oxygen the corrosion cell needs, and the reaction stops. Over loose scale, flaking, or delaminating paint, no; that material has to come off, because the coating will release with it. This is a reduced-warranty condition and we state it in writing.
How do I know if the steel is too far gone to coat?
Take ultrasonic thickness readings and compare to design. Coating restores nothing structurally — it prevents further loss. If the member is already below required section, you need a welder or a replacement, and we will say so rather than sell you material.
Can it go over existing paint?
Usually, with 7001 primer, which promotes adhesion and blocks bleed-through from aged finishes. Test a small area first: if the old coating fails cohesively when you pull on it, the whole system has to come off. Aged alkyd, epoxy, and urethane in sound condition generally accept the overcoat fine.
What about pitting — does the coating fill it?
Polyurea will bridge and fill shallow pitting, and at 20 to 60 mils it covers a lot of surface irregularity. Deep pitting with entrapped contamination is a different situation — clean it out and verify chlorides, or you are sealing salt against the steel.
Downtime & Execution
How long is the asset out of service?
Tack-free in 10 to 30 seconds and full service typically within the hour after the last pass. The schedule driver is prep and masking, not cure. Most single-asset maintenance work fits inside one shift, and there is no second coat to come back for.
Do we need containment and abrasive disposal?
Not for SP3 power-tool prep, which is one of the main reasons maintenance overcoating is affordable. Power-tool work needs dust control and appropriate PPE, particularly if lead-bearing paint is present, but it avoids the containment structure, abrasive handling, and disposal costs that come with open blasting.
Can it be sprayed while adjacent equipment is running?
Often, with proper masking. Polyurea overspray dries to dust in seconds and travels, so it needs to be controlled — but there is no extended solvent flash-off period and no lingering VOC issue keeping people out of the area. We plan the pass sequence and masking with you.
What happens when a forklift gouges it next year?
Abrade the damaged area, apply 7001 primer, respray. Minutes, not a shutdown. That local repairability is a large part of why this works on assets that get handled roughly.
Cost, Warranty & Alternatives
How does this compare to a conventional maintenance paint system?
A three-coat maintenance system means multiple mobilizations or standing crew through recoat windows, and it typically needs attention again at five to seven years. A single polyurea pass builds full thickness at once and routinely runs well past that. Compare cost per year of asset life, not cost per gallon.
What warranty applies to an overcoat?
Full warranty terms require SP6 blast, verified profile, chloride limits, and documented DFT. SP3 maintenance overcoating over tight rust carries a reduced-warranty note — we are explicit about that up front so nobody is surprised later. Many facilities take that trade knowingly because the alternative is deferring the work entirely.
Will it chalk or change color over time?
Aromatic polyurea chalks and fades in direct UV. It is purely cosmetic and does not affect the barrier or the physical properties. Where appearance matters — public-facing structures, architectural steel — we spec an aliphatic topcoat.
Do you sell direct, or only through contractors?
Both. We ship material nationwide to facilities, contractors, and distributors. Because application requires plural-component equipment, most facilities either use their existing coating contractor or ask us for a referral. Contractors and distributors get wholesale pricing — mention region and volume.
Have a Situation That Does Not Fit These Answers?
Most maintenance problems do not. Describe the asset and we will give you a straight assessment.
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