You’ve selected the right industrial coating or lining system based on your project’s requirements — operating temperatures, chemical exposure, protection level, and service environment. The system is designed to deliver the performance you need to protect vital infrastructure from corrosion, abrasion, and chemical attack.
But choosing the coating is only half the equation.
To ensure long-term performance, that coating or lining needs to bond effectively to the concrete surface. Without proper surface preparation and substrate repair, even the best coating will fail. The coating system must adhere to a sound, clean, and well-prepared surface — or it won’t last. And in many industrial environments, the concrete substrate you’re working with is far from ideal. It may be deteriorated, cracked, or contaminated with oils, chemicals, or dust. That’s why preparing and repairing concrete before applying coatings is a critical step in the application process.
Before you start applying your high-performance protective coating, here are five key factors to consider when choosing a concrete repair material:
1. Bond Strength
A strong bond between the repair material and the existing concrete is essential. If the repair doesn’t bond well, it can delaminate under thermal, mechanical, or chemical stress — compromising the entire coating system. Focus on surface prep to remove dust, grease, laitance, or chemical residues. Any contaminants left behind can act as bond breakers, preventing proper adhesion. Choose a repair product with high bond strength and follow recommended surface preparation guidelines.
2. Coating Application Method
The best repair material won’t help if it’s not applied correctly. Choose a method that ensures maximum contact with the concrete surface. Trowel-applied mortars may be faster but require experienced installers. If the geometry is complex or access is limited, form-and-pour techniques might be more effective. The goal is to achieve full contact without voids or cold joints. Always factor in your crew’s skill level, site conditions, and available tools.
3. Repaired Surface Preparation
Once the repair is complete, it must be prepped again before you can apply the coating or lining. Most protective coating systems require a specific profile — often achieved through abrasive blasting, scarifying, or grinding. The coating manufacturer’s data sheet will provide guidance. Consider how long the surface prep will take and how it fits into your shutdown schedule. If time is limited, fast-setting repair mortars may help you meet tight deadlines.
4. Cure Time
Repair materials must be cured to a certain state before they can accept a coating. Cementitious repair mortars typically need time to hydrate and release excess moisture before priming. If primed too early, moisture can get trapped and cause blistering or debonding. On the other hand, epoxy and polymer-based repairs usually need to reach a tack-free condition before priming. Cure times vary, so review the product data sheets carefully and plan accordingly.
5. Get Expert Coating Advice
New repair materials are constantly entering the market. Some are engineered to bond to damp concrete, cure quickly, or resist aggressive chemicals. Don’t rely on old solutions — talk to a manufacturer or distributor who understands the latest concrete repair technologies. They can help you find the right product for your job conditions, timeline, and coating requirements.
Proper concrete surface preparation and substrate repair are essential to the success of any industrial coating or lining project. Whether you’re lining a containment area, applying a tank coating, or protecting a processing floor, start with a strong foundation. A repair done right ensures your coating system performs as expected — protecting your investment and delivering long-term value.
Give us a call at 888-809-2365 if you have any questions about coatings or any other maintenance needs. And don’t forget to check out our line sheet to see all we have to offer!
