Railways

Protective coatings are designed first and foremost to prevent degradation, not to decorate. Their success is measured in years of corrosion resistance, not in gloss or color uniformity.

Unlike decorative or finishing coatings, which aim for visual appeal, protective coatings serve a structural purpose: they shield the substrate, often steel or aluminum, from corrosion, chemicals, abrasion, and UV. This involves selecting not just a coating type, but also applying the right system, with the right surface preparation, film build, and application method.

There are several protective technologies:

- Liquid protective coatings (typically 2K epoxies, polyurethanes, or zinc-rich primers) offer tailored barrier and cathodic protection, especially on large complex structures.

- Powder coatings offer excellent edge coverage and chemical resistance, particularly when combined with proper pre-treatment and curing.

- E-coat (electrophoretic deposition) is highly uniform and ideal for internal cavities or complex geometries, often used as a primer before topcoats in automotive and general industry.

What really sets protective coatings apart is the margin for error, or lack thereof. While a cosmetic defect in a decorative system might be tolerated, an undercured primer or a pinhole in a protective system can result in catastrophic failure over time. Key parameters include:

- Surface preparation quality (usually Sa 2½ or better)

- Correct DFT (Dry Film Thickness)

- Environmental control during application and curing

- Accurate mixing and pot life control (for multi-component systems)

Protective coatings are part of a corrosion management strategy, not just a layer of paint. Success depends on a holistic approach combining material selection, proper equipment, trained operators, and rigorous inspection.

👉 In corrosion protection, beauty is not skin deep, it’s all about what’s happening underneath.

Precision, reliability, and compatibility with your coating system are not optional — they’re essential for long-term corrosion protection.

When choosing equipment for protective coatings, you're not just buying a spray gun or pump — you're selecting a tool to apply a controlled and certified protective system. The stakes are higher than in decorative painting: a small defect today can become a big failure tomorrow.

Here’s what truly matters:

1. Material compatibility

Protective coatings are often high-solids, high viscosity, and chemically aggressive (think zinc-rich primers, epoxy mastics, or polysiloxanes). Your pumps, hoses, seals, and guns must be chemically compatible and robust enough to handle such products — especially over long projects.

2. Precise control of flow and mixing

For 2K and 3K systems, accurate ratio control is non-negotiable. Even a slight off-ratio mix can result in underperformance or premature failure. Equipment should ensure reliable dosing, mixing, and flow monitoring — ideally with automated ratio control and alarms.

3. Application consistency

Uniform film thickness is critical — whether you're applying a 75µm epoxy primer or a 500µm high-build coating. Your equipment must allow operators to maintain stable pressure, fan pattern, and spray rate, even in demanding field conditions.

4. Heating and temperature stability

High viscosity coatings often require pre-heating to reduce pressure loss and ensure good atomization — but without degrading the material. Temperature control helps maintain consistent application properties, especially in varying climates.

5. Cleaning and downtime management

Protective coatings are typically fast-curing. Equipment with efficient flushing systems, reduced dead zones, and easy maintenance will minimize downtime and reduce the risk of blockage or cross-contamination between materials.

6. Ergonomics and safety

Application is often done in harsh environments — on scaffolding, inside tanks, or in confined spaces. Choose equipment that’s ergonomic, lightweight, and designed to reduce operator fatigue while complying with ATEX and safety regulations.

Protective coating applications rely heavily on high-pressure pumps, such as our robust Sames Azur range. To enhance reliability and ease of use, Sames has introduced two major technological innovations for this demanding market.

The first is our VDE (Venturi Dual-stage Exhaust) technology, which ensures uninterrupted operation of the Azur Airless pumps. This system prevents stalling and delivers a smooth, quiet working experience. For example, when painting multiple boat hulls in a shipyard during a short weather window, professionals need absolute confidence in their equipment. With VDE, painters can focus on their work, knowing their pump will remain efficient and operational without any risk of freezing or stopping mid-job.

The second innovation is our self-strained seal technology combined with a cartridge-based design, simplifying on-site maintenance. Like most pumps in the protective coating industry, our Azur pumps use chevron-style "V" seals. Traditionally, these seals require regular manual tightening to ensure proper sealing and avoid leaks. However, it’s often unclear how frequently to tighten them—or how much—risking premature damage or downtime. Our self-strained seal system automatically maintains optimal compression, eliminating guesswork and dramatically reducing maintenance needs.

These innovations demonstrate our commitment to delivering practical, high-performance solutions that reduce downtime, enhance reliability, and keep your operations running smoothly.