In the latest episode of the “In the Mix, Choosing the Right Coating Solution” podcast, industry experts Brian Cheshire and Kurt Fuller share insights into the world of coatings for water tanks. Brian Cheshire, Director of Sales for Water and Wastewater at Tnemec, and Kurt Fuller, COO of Phoenix Fabricators and Erectors, discuss the evolution of coatings, the importance of choosing the right materials, and the benefits of fluoropolymer coatings for water tanks.
1. Evolution of Water Tank Coatings
Early Coatings: The podcast begins with a historical overview of water tank coatings. Initially, in the 1960s and 1970s, alkyd coatings, which are oil-based, were commonly used. These were simple to apply but had a short lifespan of about five years, requiring frequent maintenance and repainting.
Introduction of Polyurethanes: The late 1970s saw a shift to aliphatic polyurethanes, which offered better UV stability, weather resistance, and a longer service life of up to 10 years. This development marked a significant improvement over alkyd coatings.
Clear Coat Polyurethanes: By the 1990s, there was an attempt to extend the life of polyurethane coatings by adding a clear coat on top. However, these coatings presented application challenges and did not significantly increase the lifespan due to potential application errors, such as missing spots.
Fluoropolymer Coatings: Around the year 2000, fluoropolymer coatings were introduced to the water tank market, revolutionizing the industry. These coatings, developed initially in Japan in the 1980s, offer exceptional durability, color retention, and gloss retention, with some tanks coated with these materials potentially lasting over 30 years without needing repainting.
2. Advantages of Fluoropolymer Coatings
Extended Lifespan: One of the standout benefits of fluoropolymer coatings is their longevity. Unlike earlier coatings, which required frequent maintenance, fluoropolymers can significantly extend the repaint cycle, reducing long-term maintenance costs.
Cost Efficiency: While fluoropolymer coatings are more expensive upfront, they offer substantial cost savings over time. The podcast highlights that the actual cost of the coating material is only a small portion of the total project cost, with labor and application being the most significant expenses. Thus, a longer-lasting coating reduces the need for frequent repainting and labor costs, making it a more economical choice in the long run.
Aesthetic and Functional Benefits: Fluoropolymer coatings also provide superior color and gloss retention, enabling water tanks to maintain their appearance for longer periods. This feature is particularly beneficial for tanks used as town landmarks or with intricate designs and logos.
3. Real-World Applications and Case Studies
Phoenix Fabricators’ Experience: Kurt Fuller shares how Phoenix Fabricators have embraced fluoropolymer coatings due to their longevity and superior performance. Phoenix, often utilizing their own field painting crews, finds these coatings to be the best option for reducing maintenance issues and ensuring customer satisfaction.
Tnemec’s Value-Driven Approach: Brian Cheshire explains Tnemec’s focus on value selling, emphasizing the importance of considering the total life cycle cost of a project rather than just the initial cost. Tnemec has been successful in promoting the long-term benefits of fluoropolymer coatings, especially in projects where durability and long-term performance are critical.
4. Future of Coating Technologies
Sustainability and Innovation: The discussion concludes with a look towards the future, highlighting the growing emphasis on sustainability and life cycle costs in the coatings industry. As infrastructure ages and environmental concerns become more prominent, there is an increasing need for durable, long-lasting coatings that minimize environmental impact and reduce the frequency of repainting.
Conclusion
The podcast episode offers valuable insights into the evolution and benefits of various coating technologies, particularly the advantages of fluoropolymer coatings for water tanks. As the industry continues to innovate and prioritize sustainability, choosing the right coating solution becomes even more crucial for asset owners looking to maximize their investments and reduce long-term costs. Fluoropolymer coatings, with their superior performance and longevity, are set to play a significant role in the future of water tank coatings.
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