Why is Plastisol cladding cheaper to repaint than replace?

Replacing cladding panels requires removing all existing panels, disposing of them, installing new panels, and resealing the building envelope, a major construction project with significant cost and disruption. Recoating the existing panels on-site requires none of this structural work. The coating process restores full protective and decorative performance at a fraction of the replacement cost, typically 20–30% of the cost of like-for-like panel replacement.

Cladding Refurbishment

How to Paint Plastisol Cladding: Refurbishment Guide

Q: What is Plastisol cladding?

Plastisol is a coating material made from polyvinyl chloride (PVC) particles suspended in a plasticiser emulsion, which is then heated to form a solid flexible film. As a cladding finish it is applied in a relatively thick layer over profiled steel panels, giving good impact resistance, flexibility, and weather protection. It has been widely used on commercial, industrial, and agricultural buildings across the UK since the 1970s. Over time Plastisol fades, chalks, and can separate from the underlying metal, particularly at cut edges and fixings.

Q: What paint should be used on Plastisol cladding?

Standard decorative paints, latex, acrylic emulsion, or oil-based gloss, are unsuitable for Plastisol cladding. They lack the flexibility, adhesion, and weather resistance required for a durable result. A specialist cladding coating system is needed: a Plastisol-compatible bonding primer followed by a purpose-formulated cladding topcoat. Modern cladding topcoat systems offer extended warranties of up to 15 years depending on the product specification, colour, and site conditions.

Plastisol cladding is one of the most common building envelope materials in the UK, found on thousands of commercial, industrial, and agricultural buildings. When it weathers and fades, recoating is the most cost effective refurbishment option, provided the correct preparation and coating system is used.

Anthony Jones, Vanda Coatings Updated February 2026 8 min read Plastisol Cladding Cladding Refurbishment Technical Guide

Plastisol cladding being recoated on a commercial industrial building

Plastisol cladding serves as both the decorative and protective outer envelope of commercial buildings. When it deteriorates, through chalking, fading, delamination, or corrosion at cut edges, the building's appearance and weather resistance are both compromised. Full panel replacement is the most expensive solution; recoating the existing panels on-site is the alternative that most building owners, facilities managers, and property managers choose.

This guide explains what Plastisol cladding is, why it deteriorates, why standard paints should not be used on it, and the correct twelve-step process for a professional, durable recoat.

What is Plastisol cladding?

Plastisol is a coating material made from polyvinyl chloride (PVC) particles suspended in a plasticiser, heated during manufacture to form a solid, flexible film. When applied to profiled steel panels in a factory, it produces a coating that is:

Thick, typically 200 microns, compared to 25 microns for a standard paint film
Flexible, the PVC matrix can accommodate building movement and metal expansion
Impact-resistant, the relatively thick, soft film absorbs minor impacts that would crack a harder coating
Weather-resistant, when intact, it provides a durable barrier against rain, frost, and moderate UV exposure

Plastisol has been the dominant cladding finish for industrial and commercial buildings in the UK since the 1970s, and the majority of the single-storey commercial building stock in this country carries a Plastisol or Plastisol-derived cladding finish of some description.

Why Plastisol cladding deteriorates

Despite its initial durability, Plastisol degrades progressively over time:

UV degradation, sustained UV exposure breaks down the PVC binder and causes chalking, colour fade, and surface brittleness. South-facing elevations tend to fail significantly faster than north-facing ones.
Thermal cycling, profiled metal panels expand and contract significantly with temperature change. Over many cycles this stresses the coating at bends and profile features, eventually causing fine cracks and microdelaminations.
Cut-edge corrosion, the edges of Plastisol-coated panels are cut during manufacture, exposing raw steel. Without specific cut-edge treatment, moisture penetrates through these exposed edges and begins to corrode the substrate, undercutting the coating from behind.
Physical damage, impact from vehicles, machinery, racking systems, and hailstones damages the Plastisol film. Once the film is breached, moisture reaches the steel directly.
Delamination, gradual loss of adhesion between the Plastisol layer and the steel substrate, often beginning at fixings, cut edges, or areas of impact damage, spreading outward as moisture works beneath the film.

Do not ignore cut-edge corrosion. Rust spreading from panel edges beneath the existing Plastisol coating will not be stopped by painting over the top. Cut-edge corrosion must be treated with a specialist sealant as part of the preparation process before any topcoat is applied, otherwise the new coating will delaminate along the same path as the old one within a few years.

20–30%

of panel replacement cost, typical cost of a professional cladding recoat

10–15

years' service life from a correctly applied specialist cladding coating system

200µm

typical factory-applied Plastisol film thickness, compared to 25µm for standard paint

Any RAL

colour available, colour-change recoats completed without panel replacement

Why standard paints are unsuitable for Plastisol cladding

The most consequential decision in any Plastisol cladding recoat project is the choice of coating system. Using an unsuitable product is the single most common cause of early failure in cladding recoat work, and it is completely avoidable.

Standard paints, latex, water-based emulsion, oil-based alkyd, or general-purpose acrylic, are not formulated for Plastisol substrates. Specific problems include:

Adhesion failure, standard paints cannot achieve reliable bond to the smooth, plasticised PVC surface of Plastisol without a compatible primer. Peeling typically becomes visible within 12–24 months.
Insufficient flexibility, standard paint films crack when the cladding profile flexes. Plastisol-coated panels move significantly with thermal cycling; the topcoat must be able to flex with them.
UV degradation, standard paints that are not UV-stabilised chalk, fade, and break down rapidly on south-facing elevations exposed to direct sun.
Weather resistance, exterior cladding is subject to driven rain, frost, and temperature cycles that quickly degrade coatings not formulated for exposure class C4 or C5 environments.

The correct product is a specialist cladding topcoat, a purpose-formulated coating system designed specifically for Plastisol and steel substrates, with proven adhesion, flexibility, UV stability, and long-term weather resistance. Applied over a compatible bonding primer, this is what delivers 10–15 years of service life on a professional recoat programme.

Update, advances in cladding coating technology: Modern specialist cladding systems have significantly extended achievable warranty periods compared to products available a decade ago. Depending on the topcoat system selected, the substrate condition, and the site location, extended warranties of up to 15 years are now available, substantially exceeding what was possible with earlier product generations. A professional contractor will specify the appropriate system based on your building's exposure classification and the client's warranty requirements.

The recoating process: step by step

The following is the correct sequence for a professional Plastisol cladding recoat. The temptation to shortcut preparation is strong, particularly under time or budget pressure, but preparation quality directly determines how long the new coating lasts. A properly prepared surface with the right coating system will last 10–15 years; a poorly prepared surface will begin to fail within two or three.

Remove loose and degraded coating

All flaking, delaminating, or bubbling sections of the existing Plastisol coating must be removed before preparation begins. Wire brushing and hand scraping are suitable for localised areas of failure. Where large areas of the surface have failed, particularly common on buildings more than 20 years old, grit blasting or soda blasting may be required to return the panels to a clean, sound substrate. Only intact, well-adhered sections of the existing Plastisol should remain; loose areas must be taken back completely.

Address cut-edge corrosion

Inspect all panel edges, top, bottom, and sides, and all fixing points for evidence of cut-edge corrosion. Rust staining, lifting at panel edges, and blistering adjacent to fixings are the typical signs. Where corrosion is found, the affected area must be cleaned back to sound metal and treated with a specialist cut-edge corrosion sealant before any painting begins. This step is carried out by experienced professionals, not as a DIY measure.

Degrease the surface

The entire cladding surface must be cleaned with a specialist degreasing agent to remove mould, atmospheric dirt, oils, grease, and any other contamination. In industrial environments, surfaces may carry a film of process residue or airborne oils that are not visible to the eye but will completely prevent paint adhesion. In cases of biological contamination, algae or heavy mould growth, a sterilisation wash with a biocidal cleaner should precede the standard degreasing step.

Rinse thoroughly and allow to dry

All cleaning and degreasing products must be rinsed from the surface, residual cleaning agents left on the panels will interfere with primer adhesion. Allow the surface to dry completely. On exterior cladding this means waiting for an appropriate weather window; the surface temperature must also be above the dew point before any coating is applied to prevent condensation forming on the panel face during application.

Key the surface

The intact Plastisol surface must be abraded to provide mechanical adhesion for the primer. A suitable abrasive pad or fine-grade sandpaper is used to break the gloss and key the surface across the full area. Edges of areas where coating has been removed should be feathered, abraded to a gradual taper, so there is no visible step or edge between the bare metal area and the remaining Plastisol, which would be visible through the new topcoat.

Remove sanding dust

Dust from abrasion must be removed before priming. Blow down or brush away loose dust, then wipe the surface with a clean tack rag. Any dust particles left on the surface will be encapsulated in the primer film, producing a rough texture and reducing the quality of the final finish. This step is particularly important on profiled cladding where dust can collect in the troughs of the profile and is not always visible from a standing position.

Mask all adjacent surfaces

All areas not to be coated, windows, doors, gutters, fascias, ground areas adjacent to the building, and any other surfaces that could receive overspray, must be masked before spraying begins. On occupied commercial premises, cars, equipment, and any neighbouring property must also be protected. The extent of masking required depends on wind conditions and the proximity of adjacent surfaces; in tight locations, containment sheeting may be required around the entire working area.

Apply bonding primer

The bonding primer is the most technically critical product in the entire system. It must be specifically compatible with Plastisol, a standard metal primer or etch primer will not achieve adequate adhesion to the plasticised PVC surface. The primer is applied by airless spray to ensure even coverage across the full corrugated profile, including all troughs and ribs. Allow full cure to the manufacturer's minimum overcoating time before applying the topcoat.

Select the correct topcoat system

The topcoat must be a specialist cladding coating, not a standard decorative or industrial paint. Modern specialist cladding systems are available as single-pack or two-pack formulations with extended warranty options. The coating supplier will specify the correct product based on the substrate (Plastisol or mixed), the building's exposure classification (inland, coastal, industrial), the required colour, and the warranty period requested. Colour choice affects warranty duration, deep and dark colours absorb more solar heat, which accelerates thermal cycling stresses in the coating film.

Apply the first topcoat

The first topcoat is applied by airless spray. Correct gun distance (typically 30–35cm from the panel face), overlap, and stroke speed are maintained throughout to produce a uniform film across the full corrugated profile. Application must avoid overloading the troughs, runs in inaccessible troughs are difficult to correct and visually prominent on the finished surface. Allow to dry for approximately four hours, or the manufacturer's stated flash-off time, before proceeding.

Inter-coat preparation (where required)

Depending on the specific topcoat product and the condition of the substrate, a light abrasion between coats may be required to improve inter-coat adhesion. This is particularly relevant where the first coat has been applied over bare metal areas. Remove any sanding dust before applying subsequent coats. Follow the manufacturer's overcoating window, applying the second coat too soon or too late relative to the first can affect adhesion and final finish quality.

Apply the final topcoat

The final coat brings the surface to full colour depth and achieves the specified dry film thickness. Application technique for the final coat requires particular attention, this coat determines the visual quality of the finished surface. Consistent gun speed and overlap, correct pressure, and appropriate environmental conditions (temperature, humidity, wind speed) are all critical. Once cured, the new coating is inspected for coverage, colour consistency, and any areas requiring touch-up before masking is removed and the site is cleared.

Recoating versus panel replacement: a direct comparison

The decision between recoating and replacing Plastisol cladding panels comes down primarily to the structural condition of the existing panels. Where panels are intact, well-adhered to the building frame, and free of major corrosion or physical damage, recoating is almost always the better choice. Where panels are severely corroded, structurally compromised, or thermally degraded to the point where the base metal is losing integrity, replacement is necessary regardless of cost.

Factor	Recoating	Panel replacement
Cost	20–30% of replacement cost	Full replacement, panels, labour, waste disposal
Disruption	Minimal, building remains in use	Significant, building envelope opened, operations affected
Time on site	Days to weeks depending on area	Weeks to months for large buildings
Service life achieved	10–15 years with correct system	25+ years (new panels with new factory finish)
Environmental impact	Low, no panel waste generated	High, existing panels to landfill, new panel manufacturing
Suitability	Panels structurally sound, coating failed	Panels structurally compromised or severely corroded

At Vanda Coatings, we have been recoating Plastisol cladding on commercial and industrial buildings across the UK for nearly three decades. Every project begins with a thorough condition survey to assess the existing coating, identify any corrosion or structural issues, and specify the correct primer and topcoat system. We work with the leading specialist cladding coating manufacturers to ensure every project uses products appropriate to the substrate, the environment, and the client's warranty requirements.

Frequently asked questions

Q What is Plastisol cladding?

Plastisol is a thick, flexible coating made from PVC particles suspended in a plasticiser, heat-cured during manufacture to produce a solid film on profiled steel panels. It has been widely used as a building cladding finish since the 1970s, offering good impact resistance, flexibility, and initial weather protection. Over time it degrades through UV exposure, thermal cycling, and cut-edge corrosion, all of which can be addressed through professional on-site recoating.

Q Can you paint over Plastisol cladding?

Yes. Plastisol-coated cladding can be successfully recoated on-site without panel replacement, provided the substrate is in reasonable structural condition and the preparation process is followed correctly. A primer specifically compatible with Plastisol is required before the topcoat is applied. Using a standard or incompatible primer is the most common cause of adhesion failure in cladding recoat projects.

Q What paint should be used on Plastisol cladding?

Standard decorative paints, latex, emulsion, oil-based gloss, are unsuitable. A specialist cladding coating system is required: a Plastisol-compatible bonding primer followed by a purpose-formulated cladding topcoat. Modern specialist systems offer extended warranties of up to 15 years depending on the product, colour, and site exposure conditions.

Q How long does painted Plastisol cladding last?

A correctly prepared and applied specialist cladding coating system will typically provide 10–15 years of service life on Plastisol panels. The key factors are preparation quality, thorough degreasing, keying, and correct primer application, and the use of a cladding-specific topcoat. Cut-edge treatment is also critical; failing to seal panel edges is the primary cause of premature failure in recoat programmes.

Q Why is recoating cheaper than replacing Plastisol cladding?

Replacing cladding panels requires removing all existing panels, disposing of them, installing new panels, and resealing the building envelope. Recoating requires none of this structural work, the preparation and coating is applied to the panels in place. The result is a cost that is typically 20–30% of like-for-like panel replacement, with minimal disruption to building operations.

Q Does painting Plastisol cladding require scaffolding?

Access requirements depend on the building height and configuration. For single-storey industrial buildings, mobile elevated work platforms or tower scaffolding are typically sufficient. For multi-storey commercial buildings, full scaffolding or rope access may be required. A professional on-site spraying contractor will assess access requirements as part of the initial site survey and factor the appropriate access method into the project programme and cost.

Anthony Jones

Director, Vanda Coatings, 29 years experience

Anthony has been specifying and supervising Plastisol cladding recoat programmes on commercial and industrial buildings across the UK since the late 1990s. From single-storey warehouse programmes to multi-storey commercial buildings, correct preparation and specialist product selection are the two factors that determine whether a cladding recoat lasts a decade or fails within three years, and both start with the initial site survey.