Specialized Coatings for EV Battery Facilities

When it comes to developing coatings for electric vehicles, it’s not just for the car or truck itself. Manufacturing facilities for electric vehicles also have their specific requirements, which is an area that Sherwin-Williams specializes in.

Sherwin-Williams has made significant strides in developing specialty coatings for numerous EV battery manufacturing facilities. These include pioneering the modern shop-applied process of coating structural steel with fire-resistant materials offsite with the support of their qualified applicator network. It also includes the development of a robust coatings portfolio to help protect critical EV battery assets for both steel and concrete.

Beyond the actual coatings, they have assembled a team of EV battery manufacturing facility experts — the Construction Solutions group — that can help streamline new EV battery build projects while saving time and money.

Vikki Young, global group leader for industrial flooring R+D, Sherwin-Williams, and Joseph Windover, construction solutions executive at Sherwin-Williams Protective & Marine Coatings, discussed some of the specific needs that manufacturers are seeking.

Young said that coatings play a pivotal yet often overlooked role in the safer, faster and simpler construction of EV battery manufacturing facilities.

“The shop-applied fireproof coatings used for steel protection in EV battery manufacturing facility applications enhance the durability and longevity of the building while contributing to more efficient construction schedules and safer work environments,” Young observed.

“Additionally, high-performance flooring systems that utilize chemically resistant and moisture tolerant coatings are critical for specialized EV battery manufacturing environments, such as cleanrooms and dry rooms, where the risk of product malfunction can result in catastrophic damage,” Young added. “By safeguarding against chemical deterioration, resinous flooring systems contribute significantly to the overall safety and efficiency of EV battery facilities.”

Windover noted that these coatings are complex compared to more traditional systems. For example, epoxy Intumescent coatings can be considered more complex from a technological perspective versus traditional solvent-based coatings.

“The two parts polymerize and form a highly specialized and durable coating that is designed to withstand harsh conditions,” said Windover. “For example, epoxy intumescent coatings used for the fireproofing of EV battery manufacturing facilities contain multiple chemicals that, when heated, react to produce a charred layer that is much thicker than the original coating. This unique technology creates a layer with low thermal conductivity, slowing the rate at which heat reaches the steel and providing a buffer zone between the fire and the steel.”

Young noted that for resinous flooring systems, coatings are engineered specifically to deal with moisture and hazardous chemicals that, when not protected against, can lead to the contamination of sensitive materials such as battery components.

“Additionally, EV battery manufacturing facilities are unique operating environments with risks of electrostatic discharge, slips and falls due to substances such as carbon black,” she added. “Thermal runaway, a chain reaction that can cause a battery to overheat and potentially lead to fires or explosions, is also a risk. This warrants the need for advanced flooring systems that prevent and control these hazards.”

Young and Windover said that some of the key characteristics of EV battery manufacturing facility coatings include the following:
• Durability: In EV battery production areas, there is often heavy machinery and constant foot traffic. Flooring systems need to be durable enough to support both, without deteriorating. High traffic wear resistance helps shield the concrete from development of divots, cracking and trip hazards.
• Longevity: Unlike standard coatings, specialized floor and steel coatings are comprised of advanced materials that improve the system’s performance lifespan. This means the coatings are high-quality and able to provide exceptional functionality for longer periods of time.
• Chemical resistance: Facilities using harsh chemicals must choose coatings that can withstand exposure without degrading. For example, when standard epoxy floors are subjected to N-Methyl-2-pyrrolidone (NMP), a chemical commonly used in EV battery manufacturing, the results can be full deterioration of the coating. Sherwin-Williams has flooring systems that demonstrate NMP resistance of up to 14 days.
• Cleanability: These coatings are designed to be smooth and non-porous, which prevents particles from eroding the materials. The surface of the flooring systems is also resistant to spills and has tested above the industry standard for the dynamic slip coefficient rating. This makes the systems easier to clean and maintain.
• Abrasion resistance: The resinous coatings for the flooring systems have industry-leading abrasion resistance that is four to six times greater than standard epoxy topcoats. This means they provide premium protection to ensure the system can perform and handle the construction phase and normal operations.
• Compressive strength: The coatings are designed with compressive force in mind, which means the flooring systems are tested and measured in pounds per square inch (PSI) to determine its ability to handle the impact of EV battery facility equipment.
• Moisture tolerance: EV battery plants are particularly susceptible to moisture because it can infiltrate production areas, leading to contamination of sensitive materials. A moisture vapor barrier enhances support for clean and dry rooms.