Greenhouse gas emissions influence every stage of the built environment. Coatings sit within this picture in a complex way: they generate emissions during production, but they also protect assets and keep embodied carbon locked in place for decades. Understanding this balance is important for engineers, project specifiers and asset owners aiming to support Australia’s net-zero targets.
What Are Greenhouse Gas Emissions in Coatings Production?
Greenhouse gas emissions in coatings production refer to the carbon output, volatile organic compounds (VOCs) and other harmful emissions generated during the manufacturing, transport and application of coating materials.
In simple terms:
Coatings generate greenhouse gas emissions through energy-intensive raw materials, production processes, solvents and VOC release during application. These emissions influence air quality, embodied carbon totals and the sustainability outcomes of infrastructure projects. However concrete and steel contribute to the greatest portion of all greenhouse gas emissions of all construction materials. In comparison the environmental impact of coatings production is merely a fraction of the impact from production of concrete and steel.
Quality coatings help preserve assets and reduce long-term carbon impacts.
Understanding Greenhouse Gases and Climate Impact
Greenhouse gases trap heat in the atmosphere and contribute to climate change. While all industries emit carbon dioxide, methane and other pollutants, the coatings sector has a specific impact due to raw material production, solvent use and VOC release.
The Australasian Corrosion Association (ACA) plenary1 highlights that many materials used in coatings depend on fossil fuels, chemical reactions or high process heat, which contribute to embodied carbon.
The Coatings Industry’s Contribution to Greenhouse Gas Emissions
1. Carbon Emissions Through Raw Materials and Manufacturing
Many coating formulations rely on synthetic chemicals derived from fossil fuels. Producing these compounds generates carbon emissions during extraction, processing and transport.
Other contributors include:
- Batch production energy use
- Warehousing and transport
- Packaging materials
- Waste management during manufacturing
Although coatings represent a smaller portion of total embodied carbon in construction, their output is regulated because the VOC emissions per litre are relatively high.
2. VOCs and Their Environmental Impact
VOCs are a major concern in the coatings sector. These compounds evaporate during application and curing, releasing harmful gases into the atmosphere.
Research cited in the ACA plenary1 shows VOCs:
- Contribute to ozone formation
- Increase smog and particulate matter
- Add to the carbon footprint of coatings
- Are linked with sick building syndrome
- Pose risks to air quality and worker health
VOCs do not stay local; they become part of the broader atmospheric system, influencing climate and air quality at a regional scale.
For projects requiring coating inspection, RemedyAP’s coating inspection service provides quality control to ensure systems meet environmental expectations.
How VOCs Are Released During Coating Application
VOCs are released when a solvent evaporates from the wet coating film. This starts the moment a coating is applied and continues through the curing process. Some products can off-gas for months.
Three key factors influence VOC release:
Solvent Type
Traditional alkyds and solvent-borne systems contain higher VOC loads because they rely on hydrocarbons such as toluene and xylene.
Film Build and Chemical Composition
Low-solids coatings release more VOCs because a greater portion of each litre evaporates during curing.
Application Practices
Poor technique increases VOC emissions through:
- Overspray
- Unnecessary thinning
- Excessive clean-up solvents
- Mixing more product than required
RemedyAP’s durability assurance service helps asset owners select coating systems with reduced environmental impact across the asset lifecycle.
Carbon Emissions From Coatings in Context
A Small Percentage, but a High Responsibility
Finishes such as coatings represent 4–8% of a typical building’s upfront embodied carbon. However, the industry carries a disproportionate regulatory burden because VOCs directly impact air quality, an area where steel and concrete do not contribute in the same way.
Why This Matters
Coatings may produce emissions during application, but they prevent far greater emissions by extending the life of steel and concrete.
The ACA plenary1 includes a powerful example:
- Replacing a 9-m steel pipe = 3,211 kg CO₂e
- Coating the same pipe = 65.38 kg CO₂e
This shows that coatings reduce carbon by preserving embodied carbon within assets, delaying demolition, scrap production and new manufacturing cycles that release significant greenhouse gases.
This reinforces why coating system selection, quality control and specification all matter.
The Coatings Industry’s Response to Environmental Challenges
Advancements in Low-VOC and Eco-Friendly Formulations
Manufacturers continue to reduce solvent loads and replace hazardous raw materials. Today’s innovations include:
- Water-borne epoxies
- Low-VOC alkyds
- Powder coatings with zero solvent content
- Polyurethane systems derived from vegetable oils
- Green chemistry approaches using renewable feedstocks
- Nanotechnology-enhanced coatings that deliver durability with thinner film builds
These systems support emission reduction without sacrificing performance.
Sustainable Application Practices
In many cases, waste and emissions occur during application rather than manufacturing.
Practical improvements include:
- Using HVLP and airless spray systems to minimise overspray
- Adopting precise mixing ratios
- Reducing unnecessary thinning
- Improving solvent recovery and clean-up processes
- Implementing digital inspection tools for better quality control
Quality control reduces rework and prevents premature failures. This is where RemedyAP’s expertise supports both environmental outcomes and project efficiency.
Explore RemedyAP’s failure analysis services to understand causes of coating system breakdowns and corrective paths.
Why Coatings Matter for Net-Zero Goals
1. They Extend Asset Life and Keep Embodied Carbon Intact
Coatings protect the most carbon-intensive materials in construction: steel and concrete. When these materials are maintained rather than replaced, the embodied carbon remains locked in.
This directly supports:
- Net-zero targets
- Reduced construction waste
- Optimised lifecycle performance
- Deferred replacement of carbon-heavy materials
2. They Support Adaptive Reuse
Renovating and maintaining assets often has a far lower carbon footprint than demolition and new construction.
3. They Improve Air Quality and Reduce Harmful Emissions
Coatings with lower VOCs and improved formulations reduce health and environmental impacts during both construction and operation.
The Path to Lower Emissions in Coatings
The future of lower-emission coatings lies in:
- Continued innovation in sustainable materials
- Improved lifecycle assessment practices
- Stronger linkages between coating selection and embodied carbon targets
- Rigorous inspection and verification during construction
- Smarter maintenance schedules that reduce unnecessary repaint cycles
Coatings are only as sustainable as the way they are selected, applied and managed throughout the asset’s life.
Conclusion
Greenhouse gas emissions in coatings production come from solvents, manufacturing processes, transportation and VOC release during application. Although coatings contribute to emissions, they play a critical role in preserving steel and concrete, reducing waste and keeping embodied carbon locked into existing structures.
By selecting the right coating system, applying it correctly and verifying its performance through services such as coating inspection, durability assurance and failure analysis, engineers and asset owners can meaningfully support Australia’s net-zero goals.
The coatings industry is evolving. Through science-led innovation and responsible specification, the sector can reduce emissions while delivering the long-term durability that underpins sustainable infrastructure.
References:
Rigby, sustainability of structures and net-zero pathways