Protective Coatings Solutions

Published 5 November 2025

North America is experiencing a surge in electric vehicle (EV) battery manufacturing, with announced capacity now exceeding 1,000 gigawatt hours (GWh)—enough to power 10 million electric vehicles, according to the Environmental Defense Fund.​

As manufacturers race to meet that capacity, fast-track construction becomes the new standard. Protective coatings prove essential yet often overlooked in early planning. These advanced solutions can protect and safeguard infrastructure while maintaining tight construction timelines.

Early protective coating planning

To accelerate timelines, modular construction has been increasingly adopted to meet fast-paced, efficiency-driven goals. General contractors now deliver prebuilt sections with steel, piping, and insulation already installed. But even before these prefabricated modules leave the fabrication shop, they face risks from handling, transport, and job-site storage.

Shop-applied coating systems prove critical for maintaining schedule, quality, and budget on these types of structures.For this reason, structural steel, fireproofing, piping, and insulation packages are often coated off-site. These coatings must meet performance expectations, ensuring that structures and modules can withstand transportation, job-site storage, and final installation with minimal mechanical damage. That’s why early engagement and collaboration among coating manufacturers, architecture and engineering firms, general contractors, and the broader supply chain remain essential to ensuring optimal coating performance throughout the project lifecycle.

How to protect against corrosion and fire

Battery production environments present unique challenges to corrosive chemicals, electrostatic discharge, and fire risks. Overlooking these factors accelerates degradation, increases unplanned downtime, and, in the worst-case scenario, might result in a life-threatening situation. 

Advanced coating strategies integrated during design help mitigate those risks. When looking at corrosion protection, once unprotected, structural steel can begin corroding at the same rate as the environment to which it is exposed. Shop-applied coatings provide that primary protection. Within the vast portfolio of shop-primers, there is one specific coating type —a urethane direct-to-metal primer/finish —that provides the necessary corrosion, mechanical, and chemical protection, eliminating the risk of early corrosion, minimizing transportation damage, and reducing costly touch-up in the field. This technology also aligns with shop-applied processes and fast-track field installation.

Fireproofing protection adds another critical layer of protection. Fireproofing coatings are designed to insulate structural steel and delay heat transfer during a fire, preventing the steel from reaching its critical failure temperature, typically around 1000°F (538°C). At this temperature, steel can lose up to 50% of its strength, significantly compromising structural integrity. Mastic and thin-film Intumescent coatings are common types of fireproofing coating systems. This passive fire protection is essential for maintaining structural stability long enough to allow for safe evacuation and emergency response. It is a critical component in life safety and compliance with fire codes and building standards.

Case in point: Transport-resilient protection

The team selected an epoxy intumescent coating rated for C3 (medium) and C5 (very high) corrosivity per ISO standards. Applied off-site to more than 60,000 kg of structural steel, the coating enables controlled application conditions, reducing onsite labor and rework. 

A leading German advanced manufacturing company partnered with one of Portugal’s largest steel fabricators to construct a new manufacturing facility in Kigali, Rwanda. The project required 90-minute passive fire protection and a durable coating system capable of withstanding long-distance transport and exposure to challenging environments. 

As a result, the pre-coated steel was transported without damage, supporting a fast-track build completed in four months. The project illustrates how advanced protective coatings can enhance fire protection, structural resilience, and construction speed while contributing to sustainability through resource efficiency and waste reduction.

Don’t overlook the floor

EV facilities rely heavily on automated guided vehicles (AGVs) and forklifts—often with solid rubber tires and high wheel loads. These vehicles require floors that can withstand constant stress without failing. Thus, advanced flooring coatings must be capable of withstanding compressive loads exceeding 6,000 Lbs and enduring continuous wear from all the vehicles operating in these types of facilities. Add electrostatic discharge (ESD) specs and chemical resistance to the mix, making demands even more complex. High-performance floor systems balance all these demands to ensure long-term performance in mission-critical environments.

Explore with digital tools

Selecting the right protective coatings early in a project can accelerate decisions and reduce uncertainty. To simplify this process, digital resources such as the PPG Protective & Marine Coatings City allow specifiers, engineers, and contractors to explore system recommendations based on asset type, exposure environment, and performance needs. Tools like these can streamline coating selection, helping teams plan smarter and make faster decisions.

More than a finish
 

For battery manufacturers racing to meet demand, the right coating systems reduce rework, accelerate schedules, support sustainability and extend the facility's lifespan. From steel and insulation to flooring and fireproofing, coatings prove central to operational success. Choose partners who understand EV battery production’s complexity and timelines and can bring proven, field-tested solutions to every project.

Bruno Bruxelas is a key account manager for EV, battery and recycling plants for PPG's Protective and Marine Coatings 

Originally published in Battery Tech Online