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PROTECTING YOUR WORLD

Silo & Grain Storage Preservation

Silo & Grain
Storage
Preservation

The definitive guide to protecting your grain silos, bins, and storage facilities with advanced polyurea and protective coating systems — safeguarding your harvest, your equipment, and your bottom line.

Introduction: Why Silo & Grain Storage
Preservation Matters

Every year, farmers, grain elevator operators, and agricultural businesses across North America invest billions of dollars into harvesting crops — only to lose a significant portion of that value due to inadequate silo and grain storage preservation. Whether it’s steel grain bins corroding from the inside out, concrete silos developing micro-cracks that allow moisture infiltration, or wooden storage structures succumbing to rot and pest damage, the cost of neglecting your grain storage infrastructure is staggering.

Silo and grain storage preservation is not simply a maintenance task — it is a mission-critical investment that directly impacts food safety, crop value, operational efficiency, and regulatory compliance. The right protective coating system can extend the life of your grain storage assets by 20 to 30 years, prevent catastrophic structural failure, and ensure that every bushel you store maintains its quality from harvest to market.

At ArmorThane, we have spent decades engineering and delivering industry-leading polyurea and protective coating systems specifically designed for the unique demands of agricultural grain storage environments. This comprehensive guide covers everything you need to know about silo and grain storage preservation — from understanding the threats to choosing the right coating solution for your specific application.  

$26B+

Annual Global Grain Loss in Storage

35%

Reduction in Grain Loss with Proper Coatings

25+ Yrs

Lifespan Extension with Polyurea Coatings

500%

Potential ROI on Coating Investment
Silo & Grain Storage Preservation Matters
Key Takeaway: Proper silo and grain storage preservation using modern polyurea coating systems can reduce grain loss by up to 35%, extend asset lifespan by 20+ years, and deliver an ROI of 300–500% over the life of the structure. This is not optional maintenance — it is essential asset protection.

The Billion-Dollar Problem:
Grain Losses in Storage

The global challenge of post-harvest grain loss represents one of the most pressing issues in modern agriculture. According to the Food and Agriculture Organization of the United Nations (FAO), approximately 14% of all food produced worldwide is lost between harvest and the retail level — and a substantial portion of this loss occurs directly within storage facilities. In the United States alone, the USDA estimates that improper grain storage conditions contribute to hundreds of millions of dollars in losses annually.

These losses manifest in several ways. Moisture infiltration through compromised silo walls or roof structures promotes mold growth, mycotoxin contamination, and spoilage that can render entire grain stores unsaleable. Structural corrosion in steel bins creates rust contamination and compromises the physical integrity of the silo itself. Temperature fluctuations caused by poor insulation allow condensation to form inside bins, creating the ideal environment for harmful bacteria and insects. And grain dust accumulation in poorly sealed structures presents serious explosion risks that have caused tragic fatalities at grain elevators across the country.

The economic impact extends beyond the immediate value of lost grain. Contaminated grain carries regulatory consequences — grain that tests positive for aflatoxins or other mycotoxins may be rejected outright by commodity purchasers or require costly remediation. Structural failures in silos require emergency repair or complete replacement at costs that can run into the hundreds of thousands of dollars. And the reputational damage to a grain operation known for quality control problems can be nearly impossible to overcome.  
Billion-Dollar Problem Grain Losses in Storage
The solution to this multi-billion-dollar problem is systematic, proactive silo and grain storage preservation — beginning with the application of high-performance protective coatings that seal out moisture, resist chemical attack, and create a physical barrier between stored grain and the structural elements of the storage facility. This is precisely where ArmorThane’s polyurea coating systems deliver unmatched value.

Top Threats to Silo & Grain Storage Integrity

Understanding the specific threats facing your silo and grain storage structures is the first step toward implementing an effective preservation strategy. Each type of threat requires a tailored approach, and modern polyurea coating systems are engineered to address the full spectrum of these challenges simultaneously.

1. Corrosion & Oxidation in Steel Grain Bins

Steel grain bins are the most common form of bulk grain storage in North America, and corrosion is their most persistent enemy. The interior environment of a grain bin is surprisingly aggressive — grain dust, organic acids, carbon dioxide produced by respiration, and fluctuating humidity levels combine to create conditions that accelerate electrochemical corrosion at rates far exceeding what would occur in a typical outdoor environment. Roof seams, bottom rings, and wall panels are particularly vulnerable, and once corrosion begins, it progresses exponentially as the pit becomes a reservoir for moisture and grain fines.

2. Moisture Infiltration & Condensation

Water is the single greatest enemy of stored grain quality. Grain stored at moisture levels above 14% is at serious risk of spoilage, and even brief exposure to elevated humidity can initiate mold and mycotoxin development that quickly renders an entire lot unsaleable. Moisture enters grain storage structures through roof leaks, wall penetrations, foundation seepage, and condensation forming on cold surfaces during temperature transitions. An effective grain storage preservation system must create a completely watertight envelope around the storage structure.

3. Concrete Carbonation & Cracking in Concrete Silos

Concrete silos present a different set of challenges. Over time, atmospheric carbon dioxide penetrates the concrete matrix in a process called carbonation, which gradually reduces the alkalinity of the concrete and causes steel reinforcement to corrode — expanding as it rusts and creating internal pressure that eventually produces spalling and cracking. Once concrete begins to crack, water infiltration accelerates the process dramatically. Concrete dust and aggregate contamination of stored grain create food safety issues and potential equipment damage.

4. Chemical Attack from Fumigants & Grain Treatments

Grain storage facilities regularly employ chemical fumigants such as phosphine gas to control insect infestations. These chemicals are highly reactive and can attack unprotected metal surfaces, seals, and structural materials. Similarly, grain dust itself contains oils, enzymes, and organic acids that slowly degrade unprotected surfaces. A high-performance chemical-resistant coating system is essential for protecting silo infrastructure from these ongoing chemical attacks.

5. Structural Impact Damage from Loading & Equipment

The processes of filling and emptying grain storage structures create significant mechanical stresses. Grain flowing at high velocity impacts interior surfaces with considerable force, creating abrasive wear. Heavy equipment operating near grain bins can cause ground vibration and physical impact damage. Conveyor systems, augers, and bucket elevators subject silo components to repeated mechanical loading that can initiate fatigue cracking in welds and structural connections.

Silo & Grain Storage Integrity

⚠ Common Threat Sources

✅ ArmorThane Polyurea Protection

Polyurea Coatings: The Ultimate Grain
Storage Preservation Solution

Over the past two decades, polyurea elastomeric coatings have emerged as the gold standard for industrial protective coating applications — and for grain silo and storage preservation, they represent a generational leap beyond traditional coating technologies. Understanding why polyurea is uniquely suited to grain storage applications requires a brief examination of the chemistry and properties that set it apart.

Polyurea is a two-component coating system formed by the rapid reaction of an isocyanate component with an amine-terminated resin. The result of this reaction is a cross-linked elastomeric polymer with a combination of properties that no other single coating technology can match: extreme elongation and flexibility (up to 500%), outstanding tensile strength, rapid cure times (gel time as fast as 5 seconds), excellent adhesion to properly prepared substrates, and formidable resistance to moisture, chemicals, abrasion, and impact.

For grain storage applications specifically, these properties translate into real-world performance advantages that directly protect the value of stored grain and the structural integrity of the storage asset. ArmorThane has developed a comprehensive range of polyurea and hybrid coating systems specifically optimized for agricultural grain storage environments, with formulations available for interior liner applications, exterior waterproofing, structural reinforcement, and specialty applications including food-contact safe surfaces.  

Why Polyurea Outperforms Every Other Grain Storage Coating Option

Traditional approaches to grain silo preservation have included epoxy coatings, polyurethane systems, rubberized asphaltic membranes, and simple paint-grade products. While each of these has some merit in specific applications, none can match the comprehensive protective capability of a properly formulated and applied polyurea system. Here is why:

Epoxy coatings offer good chemical resistance but are rigid and brittle — they crack when the substrate moves due to temperature cycling or structural loading, creating pathways for moisture infiltration that are worse than no coating at all. Polyurethane systems are more flexible than epoxies but are moisture-sensitive during application and offer less chemical resistance than polyurea. Asphaltic products can off-gas volatile compounds that contaminate stored grain and break down under UV exposure. Paint-grade products are simply not adequate for the demands of a grain storage environment.

Polyurea eliminates all of these drawbacks. It cures instantly regardless of ambient humidity, maintains flexibility across a temperature range of -60°F to 350°F, offers outstanding chemical resistance across a broad pH range, and achieves full structural strength in minutes rather than days or weeks. A single application of ArmorThane polyurea creates a seamless, monolithic membrane that covers the entire interior or exterior surface of a grain storage structure with zero joints, seams, or overlaps — eliminating the failure modes that plague all other coating systems.
Polyurea Coatings

ArmorThane Polyurea Products for Grain Storage

ArmorThane’s product line for grain storage preservation applications includes a range of specifically engineered systems designed for the varying demands of different storage configurations and environmental conditions. Our agricultural specialists can help determine the optimal product system for your specific application, substrate condition, and performance requirements.

ArmorThane Agricultural Advantage: All ArmorThane polyurea formulations for interior grain storage applications are engineered to meet USDA and FDA guidelines for food contact surface applications, ensuring that your coating investment does not create new food safety compliance concerns. Our systems are also VOC-compliant and designed for minimal disruption to ongoing facility operations.

Top Threats to Silo & Grain Storage Integrity

Effective grain storage preservation encompasses a wide range of specific applications, each presenting its own unique challenges and performance requirements. ArmorThane’s coating systems have been successfully deployed across the full spectrum of grain storage environments and structure types.

Steel Grain Bin Interior Lining

The interior surface of a steel grain bin is continuously exposed to moisture from grain respiration, organic acids from grain decomposition, abrasive grain flow during filling and emptying, and chemical attack from fumigants. An ArmorThane polyurea interior liner creates a continuous, impermeable barrier that completely isolates the steel structure from these corrosive elements. The coating’s flexibility allows it to move with the bin walls as they expand and contract with temperature and grain load changes without cracking or delaminating. Interior liner applications typically range from 60 to 120 mils in thickness depending on the level of abrasion resistance required.

Grain Bin Floor & Foundation Coating

The floor and foundation area of a grain storage structure is subjected to the highest concentration of mechanical stress, moisture, and grain fines accumulation. This is the area where corrosion and structural deterioration most commonly begin. ArmorThane floor coating systems for grain storage applications are formulated for maximum abrasion resistance and chemical resistance, with texturing options available to improve grain sweep efficiency and reduce static grain accumulation in floor seams and transitions.

Roof & Exterior Waterproofing

The roof of a grain storage structure is the primary point of vulnerability for water infiltration. Roof seams, fasteners, and penetrations are subject to ongoing movement from thermal expansion and contraction, and standard roofing materials will eventually fail at these stress points. ArmorThane’s exterior polyurea roof coating systems create a seamless, monolithic waterproof membrane over the entire roof surface that eliminates all penetration points and bridges all seams and fastener heads. The coating’s elongation capability allows it to accommodate thermal movement without cracking, providing decades of leak-free protection even in the harshest agricultural environments.

Grain Elevator & Conveyor System Protection

The mechanical systems associated with grain storage — including bucket elevators, drag conveyors, belt conveyors, and pneumatic systems — are subjected to intense abrasive wear from grain flow. ArmorThane’s ultra-high-abrasion-resistance polyurea systems are used to line the interiors of elevator legs, conveyor housings, transitions, and spouts, dramatically extending equipment service life and reducing the maintenance costs associated with these high-wear components. Equipment coated with ArmorThane systems typically achieves 5 to 10 times the service life of uncoated or paint-coated equipment under the same operating conditions.

Grain Storage Tank & Hopper Lining

Round hopper-bottom tanks and flat-bottom storage tanks used for specialty grain storage require a coating system that can handle complex geometries while maintaining consistent film thickness and adhesion. ArmorThane’s spray-applied polyurea systems conform to any geometry — curves, angles, welds, and penetrations — delivering consistent protection across the entire surface area with no bridging failures or thin spots at complex intersections. This is a critical advantage over rolled or brush-applied systems, which inevitably leave inadequately coated areas at complex geometric transitions.
Key Silo & Grain Storage Preservation Applications

The Professional Application Process for Grain
Storage Coatings

The Professional Application Process for
Storage Coatings Grain

The performance of any protective coating system is fundamentally determined by the quality of the surface preparation and the precision of the application. A premium polyurea formulation applied over inadequately prepared substrate will fail prematurely — wasting the investment and leaving the structure unprotected. ArmorThane’s certified applicator network follows a rigorous, industry-standard application protocol for all grain storage preservation projects.
01

Site Assessment & Substrate Evaluation

Every grain storage preservation project begins with a comprehensive site assessment conducted by an ArmorThane-certified coatings specialist. This assessment includes visual inspection and documentation of existing surface conditions, moisture meter readings at multiple locations, adhesion testing on representative substrate areas, identification of any existing coating that may require removal, and determination of ambient and substrate temperature and humidity conditions. The assessment results in a detailed project specification that defines the surface preparation requirements, coating system selection, application parameters, and expected performance outcomes.

02

Equipment Setup & Environmental Control

Pure polyurea coating systems require specialized plural-component spray equipment capable of heating both components to 140–160°F and delivering them at pressures of 2,000–3,500 PSI with precise ratio control. ArmorThane applicators utilize state-of-the-art proportioning equipment, high-capacity heater systems, and purpose-built spray guns to ensure that the polyurea reaction occurs precisely as specified by the formulation chemistry. Environmental control — including temperature, humidity, and ventilation — is monitored continuously throughout the application process to ensure optimal cure conditions.

03

Polyurea Application & Film Build

The polyurea coating is applied in multiple passes to achieve the specified dry film thickness, with each pass applied before the previous pass has fully cured to ensure chemical crosslinking between layers. Application rate, pass speed, gun distance, and spray angle are carefully controlled to maintain consistent film thickness across all areas of the substrate. Complex geometrical areas — including corner transitions, weld seams, penetrations, and fastener heads — receive additional detail application to ensure adequate film build at these critical areas. Wet film thickness is monitored continuously during application using calibrated gauges.

04

PENETRATION & DETAIL WORK

Pipe boots, drains, HVAC curbs, parapet walls, expansion joints, and all roof penetrations are detailed with compatible sealant, flashing tape, or an embedded fabric reinforcement layer before coating. These transitions are where the majority of roof failures originate. Proper detailing is the most important work on any roof coating job.

05

Quality Control Inspection & Testing

Upon completion of the coating application, a comprehensive quality control inspection is conducted. Dry film thickness measurements are taken at a density of not less than one reading per 100 square feet of coated surface, with additional readings at all geometrically complex areas. Holiday (pinhole) detection testing is performed using electronic holiday detectors calibrated to the appropriate voltage for the specified film thickness. Adhesion pull-off testing is conducted at representative locations to verify the coating-to-substrate bond strength. All test results are documented and provided to the facility owner as part of a comprehensive project completion report.

06

Cure, Return to Service & Long-Term Maintenance

ArmorThane polyurea systems cure extremely rapidly — most formulations achieve walk-on strength within 30 seconds of application and are ready for light service within 24 hours. Full chemical cure and maximum physical properties are typically achieved within 7 days. Return-to-service timelines for grain storage applications are dramatically shorter than competing coating systems, minimizing downtime during the critical pre-harvest preparation period. ArmorThane applicators provide facility owners with a comprehensive maintenance guide and recommended inspection schedule to ensure the long-term performance of the coating system.

Grain Storage Coatings

Polyurea vs. Traditional Grain Storage Coating Methods

When evaluating protective coating options for your grain storage facility, it is essential to compare the performance characteristics that matter most in an agricultural environment. The following comparison presents an objective assessment of polyurea systems versus the most commonly used alternatives.

Performance Characteristic ArmorThane Polyurea Epoxy Coating Polyurethane Paint / Enamel
Cure Time (Return to Service) 30 sec – 24 hr 24–72 hours 8–24 hours 2–8 hours (light)
Moisture Sensitivity During Application None High High Moderate
Elongation at Break Up to 500% 2–5% 100–200% <5%
Chemical Resistance (Fumigants) Excellent Good Fair Poor
Abrasion Resistance Excellent Good Good Poor
Waterproof (Seamless Membrane) Yes Yes (if no cracks) Yes (if no cracks) No
Crack Bridging Capability Excellent Poor Moderate None
Temperature Range -60°F to 350°F 32°F to 200°F 20°F to 250°F 0°F to 150°F
Expected Service Life 20–30+ years 5–10 years 7–12 years 2–5 years
USDA/FDA Compliant Options Yes Limited Limited Limited
Life-Cycle Cost (20-Year) Lowest Moderate Moderate Highest

ROI & Cost Savings of Proper Grain Storage Preservation

The financial case for investing in a premium grain storage preservation coating system is compelling when viewed through the lens of total cost of ownership and the value of the grain assets being protected. Facility owners who evaluate coating investments solely on the basis of upfront cost miss the substantially larger financial picture that emerges when all the benefits of effective preservation are quantified.

Quantifying the Value of Grain Protection

Consider a grain elevator operator managing a storage capacity of 500,000 bushels of corn. At a market price of $5.00 per bushel, the total value of grain in storage at any given time is $2.5 million. Research consistently demonstrates that inadequate storage protection results in grain losses of 2–5% annually through spoilage, moisture damage, and contamination. At the low end of this range, a 2% annual loss represents $50,000 in direct grain value destruction — every single year. A comprehensive polyurea coating system for a facility this size might cost $150,000 to $200,000 — meaning it pays for itself in grain preservation value alone within 3 to 4 years, and then continues generating savings for the next 20+ years of its service life.

Structural Asset Protection Value

Beyond the direct grain preservation value, a protective coating system preserves the capital value of the storage structure itself. A steel grain bin that would cost $300,000 to $500,000 to replace can be maintained in excellent structural condition for 30 or more years with proper coating maintenance — versus developing serious corrosion problems within 10 to 15 years without any protection. The replacement cost avoidance delivered by a coating system represents a return on investment that dwarfs the initial coating expenditure many times over.

Regulatory Compliance & Insurance Benefits

Grain storage facilities that demonstrate proactive maintenance and protective coating programs also benefit from reduced regulatory scrutiny, improved grain testing outcomes, and in many cases reduced insurance premiums. Insurance underwriters for agricultural facilities increasingly recognize the risk reduction value of comprehensive coating programs and may offer premium reductions or improved coverage terms to facilities that can document their preservation activities.

ArmorThane Agricultural Advantage: All ArmorThane polyurea formulations for interior grain storage applications are engineered to meet USDA and FDA guidelines for food contact surface applications, ensuring that your coating investment does not create new food safety compliance concerns. Our systems are also VOC-compliant and designed for minimal disruption to ongoing facility operations.

Polyurea vs. Traditional Grain Storage Coating Methods

Protect Your Grain Storage Investment Today

Get a free consultation with an ArmorThane agricultural coatings specialist and discover how our polyurea systems can protect your grain storage assets for 25+ years.

Choosing the Right Coating Contractor
for Your Grain Storage Project

The performance of your grain storage coating system will ultimately be determined by the quality of the contractor who applies it. Polyurea application is a technically demanding discipline that requires specialized equipment, extensive training, and deep experience with agricultural applications. The following criteria should guide your contractor selection process.

Certification & Training

ArmorThane maintains a network of certified applicators who have completed comprehensive training in polyurea application fundamentals, agricultural grain storage applications, surface preparation standards, quality control procedures, and safety protocols. When evaluating contractors, verify that they have completed ArmorThane’s certification program and have documented experience with projects of a scale and complexity comparable to your grain storage facility. Ask for references from agricultural clients specifically — experience with industrial or commercial applications does not automatically translate to competence in the unique demands of grain storage environments.

Equipment Capability

Polyurea application requires purpose-built plural-component spray equipment capable of heating, pressurizing, and precisely rationing both components of the coating system. The leading equipment brands in the industry include Graco, Gusmer, and PMC. Verify that your contractor operates well-maintained, appropriately sized equipment for your project scale. Undersized or poorly maintained equipment will produce inconsistent film thickness, improper mix ratios, and inadequate spray patterns — all of which compromise coating performance.

Surface Preparation Capability

A contractor who cannot perform or properly supervise the required surface preparation is not capable of delivering a successful coating project, regardless of their skill with the spray gun. Verify that your contractor has access to the appropriate abrasive blasting or mechanical surface preparation equipment required for your substrate type, and that they understand the surface profile and cleanliness standards specified for the coating system.

Project Documentation & Warranty

Professional coating contractors provide comprehensive project documentation including surface preparation records, ambient condition logs, coating material batch numbers, wet and dry film thickness records, and quality control inspection reports. Insist on receiving a complete project documentation package upon project completion. Also verify the warranty terms for both the coating material and the contractor’s workmanship, and ensure that the warranty specifically covers the agricultural grain storage application environment.
Grain Storage Project

Frequently Asked Questions:
Silo & Grain Storage Preservation

Yes. ArmorThane formulates specific polyurea products that comply with USDA and FDA regulations for incidental food contact applications. These products have been independently tested and certified to confirm that they do not off-gas harmful compounds under normal grain storage conditions and do not transfer contaminants to stored grain. When properly applied and fully cured, ArmorThane’s food-contact compliant polyurea systems are completely inert in grain storage environments. Always confirm with your ArmorThane representative that the specific product specified for your project is the appropriate food-contact compliant formulation.

The total project duration depends on the size and condition of the grain storage structure, but most single-bin interior lining projects can be completed within 2 to 5 days from start of surface preparation through coating completion and quality control inspection. Because polyurea cures extremely rapidly — achieving walk-on strength in seconds and light service readiness within 24 hours — the bin can typically be returned to grain storage service within 48 to 72 hours of coating completion. This dramatically shorter downtime period compared to epoxy or polyurethane systems is a critical advantage for operations with limited pre-harvest preparation windows.

When properly applied over adequately prepared substrate and maintained according to the manufacturer’s recommendations, ArmorThane polyurea coating systems routinely achieve service lives of 20 to 30 years in grain storage applications. The key determinants of service life are the quality of the initial surface preparation, the coating film thickness achieved, and the frequency and quality of routine maintenance inspections. ArmorThane recommends annual visual inspections of all coated grain storage surfaces, with periodic adhesion testing every 5 years to verify the ongoing integrity of the coating-to-substrate bond.

In many cases, yes — but the condition and adhesion of the existing coating must be carefully evaluated before proceeding. If the existing coating is firmly adhered, in sound condition, and compatible with the specified polyurea system, it may be possible to apply the new polyurea over the existing coating after appropriate surface preparation. However, if the existing coating shows signs of delamination, blistering, cracking, or contamination, complete removal is required before the new polyurea system is applied. Attempting to overcoat failed or poorly adhered existing coatings will result in premature failure of the new system as well. Your ArmorThane coatings specialist will evaluate the existing coating condition and provide a specific recommendation.

On a first-cost basis, polyurea typically represents a higher initial investment than epoxy or polyurethane systems. However, when evaluated on a life-cycle cost basis — accounting for the much longer service life of polyurea (20–30 years versus 5–10 years for epoxy), the lower maintenance requirements, the superior grain protection performance, and the avoidance of premature recoating cycles — polyurea consistently delivers the lowest total cost of ownership of any grain storage coating option. Most ArmorThane clients who perform a rigorous life-cycle cost analysis conclude that polyurea is not the expensive option — it is the most cost-effective option available.

ArmorThane’s certified applicator network has successfully completed grain storage coating projects ranging from small on-farm bins of 5,000-bushel capacity to commercial grain elevator facilities with multiple million-bushel storage structures. The spray-applied polyurea system is highly adaptable to structures of any size and configuration. For very large projects, multiple application crews and proportioning units may be deployed simultaneously to complete the project within the required timeframe. Contact your ArmorThane representative to discuss the specific project scale and any logistical requirements for your facility.

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50+

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100%

Seamless Barrier

30s

Full Cure Time
Tyler Gleckler - ArmorThane blast mitigation specialist author photo

ABOUT THE AUTHOR

TYLER GLECKLER

Tyler Gleckler is a coatings specialist with deep field expertise in polyurea, polyaspartic, and high-performance protective systems. His writing appears regularly in Polyurea Magazine, the American Polyurea Organization, ArmorThane’s technical library, and a range of industry publications. He focuses on translating laboratory chemistry into specifications that engineers, owners, and applicators can actually deploy.

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