Large facilities rarely have the luxury of shutting down operations for maintenance or upgrades. Airports, hospitals, manufacturing plants, government buildings, universities, and corporate campuses must remain functional while improvements are made. That reality makes phased coatings projects not just helpful—but essential.

When properly planned, a phased approach allows coatings work to proceed efficiently, safely, and with minimal disruption. When poorly planned, it can lead to schedule conflicts, quality issues, and unnecessary rework. Understanding how to plan and execute phased coatings projects is key to protecting both the facility and the investment.

What Is a Phased Coatings Project?

A phased coatings project divides the scope of work into manageable sections or stages, allowing areas of a facility to remain operational while others are being coated. Each phase is scheduled, coordinated, and executed independently, but as part of a larger, cohesive plan.

Phasing is common in large facilities where coatings are applied to:

  • Multiple buildings or wings

  • High-traffic interior spaces

  • Industrial or mission-critical areas

  • Exterior façades and structural elements

  • Occupied or secure environments

The goal is to balance progress, quality, safety, and continuity of operations.

Start with a Comprehensive Facility Assessment

Successful phasing begins with understanding the facility as a whole. Before defining phases, teams must evaluate:

  • Building layout and circulation patterns

  • High-use and restricted areas

  • Existing substrate conditions

  • Environmental factors such as ventilation and humidity

  • Safety requirements and access limitations

This assessment helps identify which areas can be addressed early and which require more coordination. In many cases, prioritizing areas with deteriorating coatings or higher exposure risks helps extend the facility’s overall lifespan.

Define Clear Project Phases and Boundaries

Each phase should be clearly defined with physical and operational boundaries. Ambiguous phasing can create overlap, confusion, and inefficiencies. Clear boundaries help ensure:

  • Crews know exactly where work begins and ends

  • Facility staff understand which areas will be affected

  • Safety controls and containment measures are properly maintained

Phases may be organized by floor, building section, department, or function. In large facilities, sequencing often follows operational logic—addressing lower-traffic or support spaces first before moving into higher-visibility areas.

Coordinate Closely with Facility Operations

One of the most critical elements of phased coatings planning is coordination with facility stakeholders. This includes operations managers, safety officers, security teams, and building occupants.

Coatings work often involves odors, noise, access restrictions, and temporary shutdowns of specific areas. Early coordination allows teams to:

  • Schedule work during off-hours or low-traffic periods

  • Align phases with operational calendars or maintenance windows

  • Communicate expectations clearly to occupants and staff

This collaboration reduces disruption and builds trust between project teams and facility leadership.

Select Coating Systems That Support Phasing

Not all coating systems are equally suited for phased projects. Fast-curing, low-VOC, and low-odor coatings are often preferred in occupied environments because they allow areas to return to service quickly.

Coating selection should consider:

  • Cure times and re-occupancy requirements

  • Durability based on area use

  • Environmental and regulatory compliance

  • Maintenance needs between phases

Using compatible systems across phases also ensures visual and performance consistency throughout the facility.

Plan for Safety and Containment

Safety becomes more complex when coatings are applied in active facilities. Each phase must include a clear safety plan that addresses:

  • Access control and wayfinding

  • Containment of dust, overspray, and fumes

  • Coordination with other trades working nearby

  • Compliance with OSHA and site-specific safety standards

Phased work often means safety plans evolve over time. Regular reviews help ensure that controls remain effective as work progresses from one area to the next.

Maintain Consistent Quality Across Phases

One of the biggest risks in phased projects is inconsistency. Changes in crew assignments, schedules, or materials can lead to variations in appearance or performance.

To maintain consistency:

  • Use standardized surface preparation and application procedures

  • Document coatings systems and application methods thoroughly

  • Conduct quality control inspections at the end of each phase

  • Ensure transitions between phases are seamless

Clear documentation and communication help ensure the final result looks and performs as a unified system—not a patchwork of separate efforts.

If you want to learn How We Ensure Consistency in Quality Across Different Industries, read our blog post.

Build Flexibility into the Schedule

Large facilities are dynamic environments. Unexpected changes—such as operational needs, security events, or weather conditions—can impact phasing plans. Building flexibility into the schedule helps teams adapt without compromising quality.

A realistic phased schedule includes:

  • Buffer time between phases

  • Contingency planning for delayed access

  • Regular check-ins to adjust sequencing as needed

This adaptability is often what separates successful phased projects from problematic ones.

Why Phased Planning Protects Long-Term Value

A well-executed phased coatings project does more than minimize disruption—it protects the facility’s long-term performance. Proper sequencing, material selection, and coordination ensure coatings systems are applied correctly and maintained consistently over time.

For large facilities, this approach helps extend service life, reduce future maintenance costs, and support safe, functional environments without unnecessary downtime.

Conclusion

Planninreg a phased coatings project for a large facility requis more than dividing work into sections. It demands a strategic, collaborative approach that aligns coatings expertise with operational realities.

When done right, phased coatings projects deliver durable, high-quality results while allowing facilities to continue serving their occupants. With careful assessment, clear phasing, strong coordination, and disciplined execution, large facilities can achieve long-term protection without sacrificing productivity. Ready to start your project? Call the coatings experts!