How to formulate chemical-resistant coatings?
Last update on Feb 12, 2026
Almost all coatings at some point get exposed to chemicals and acids, whether cleaning products, spills, or fumes. In the absence of a suitable protective coating, substrates are vulnerable to absorption of solvents, acids, alkalis, salts, and other substances, leading to degradation and contamination.
In many cases, the damage from harsh solvents will become irreparable if ignored over time. So how can you make sure your coating is well protected? Let’s find out!
Underlying Requirements
Before we talk about the materials, let’s look at some pre-requisites you can tick off from your list.
- Cross-link density of the binder system: Increasing the cross-link density is a reasonable approach to control the chemical resistance of polymer networks. The higher it is the better. Below is an investigation on the chemical resistance to dimethyl methylphosphonate (DMMP, Soman simulant) on fluorinated epoxy (F-EP) and epoxy (EP) coatings.
Source: American Chemical Societya
- 2K systems over 1K: They have superior adhesion, durability, resistance to heat and moisture, and up to 85% better staining/chemical resistance compared to their 1K counterpart.
Note: If you cannot compromise on the flexibility of the coating, make sure the cross-link density of the 2K system is not too high, else the system becomes brittle, and the flexibility is lost. Balance is the key here!
Formulation strategies
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- (n.d.). How Thioplast™ polysulfides improve the flexibility and chemical resistance of epoxies. Lawrence Industries.
- (2023). The Chemistry of Epoxy. LinkedIn.
- (2024). Inert Pigment. CorrosionPedia.
- (n.d.). Chemical resistance. Daikin Global.
- (n.d.).PU Chemical Resistance: General Information. ERIKS.
- (2024). Vinyl Ester Resin Chemical Resistance. CorrosionPedia.
- (2024). Understanding Silicone Chemical Compatibility: A Comprehensive Guide. AtlasFiber.