The Prevention System

Corrosion on steel is an electrochemical cell: you need metal, oxygen, and an electrolyte in contact at once. Break any leg and the reaction stops. Prevention coatings work by removing the electrolyte path — but only if the barrier is continuous, thick enough that diffusion is negligible, and bonded well enough that water cannot creep underneath from a defect.

Thin-film paint systems struggle on all three counts. They shrink as solvent leaves, they thin at edges and welds, and they rely on multiple coats bonding to one another across cure windows. Every one of those is a place for the barrier to become discontinuous.

OR93BL is 100% solids: two components meet at the gun at roughly 160°F and 2,000 PSI, mix by impingement, and polymerize on the substrate in 3 to 6 seconds. Nothing evaporates, so wet mils equal dry mils. One pass builds the entire specified thickness, so there are no inter-coat interfaces at all. And because it gels before it can flow, edges and corners hold the same film as flat panel.

On new steel it is also simply faster. A three-coat industrial system occupies shop floor for days. This occupies it for an hour.

Blast: SSPC-SP6 commercial blast cleaning with a 2–4 mil angular anchor profile. Verify with replica tape, not by eye. On new steel this is straightforward — there is no scale-loading problem and no lead abatement to plan around.

Timing: Coat within the same shift. Blasted carbon steel flash-rusts in ordinary shop humidity within hours; a rusted profile is no longer the surface you paid to create. Where a part must sit, dehumidify the staging area or reblast.

Chlorides: Verify below 7 µg/cm² for anything shipping into coastal, road-salt, or wash-down service. New steel is not automatically salt-free — mill handling, transport, and outdoor storage all deposit it.

Galvanized and shop-primed parts: Do not blast to white. Sweep-blast or abrade, then apply 7001 primer before the polyurea. The primer both promotes adhesion and blocks bleed-through from the existing shop coat.

Wood and concrete components: Wood must be dry and sound; concrete profiled to CSP 3–5 with moisture vapor emission checked. Both take 7001 primer first.

Edges and welds: Break sharp edges where practical and stripe-coat weld toes with an additional pass before the full-coat. Polyurea holds film at corners far better than a conventional coating, but stripe-coating is still cheap insurance on a part you will never see again.

Pick by the environment the finished part enters, not by what it looks like on the rack.

OR93BL — atmospheric exposure, weather, humidity, condensation, chemical splash. Best cost per square foot and the right default for structural and enclosure steel.

Flak Jacket 1 (FJ1) — parts that will be walked on, loaded, or struck. OEM equipment decks, truck and trailer beds, roof panels, platform steel.

Flak Jacket Pro — parts where material flows across the surface. Buckets, chutes, liners, hoppers, dump bodies handling aggregate.

7001 Primer — required on galvanized, previously primed, wood, concrete, and membrane substrates. Not needed on clean blasted carbon steel.

Give us the part list and the destination environment and we will build the spec. We would rather size it right than sell you the expensive grade across the board.