This product is carefully formulated using epoxy resin and functional curing agents. It features high reactivity, strong adhesion, high cross-link density, and excellent resistance to chemicals, solvents, cathodic disbondment, as well as superior flexibility and impact resistance.
Suitable for anti-corrosion of oil and gas transmission pipelines, municipal water supply, drainage, sewage, circulating water, chemical industry, and can also serve as a base layer for anti-corrosion in thermal insulation and submarine cable applications.
Powder Coating Performance Parameters
| Test Item | Technical Specification | Remarks |
|---|---|---|
| Appearance | Uniform color, no lumps | Visual inspection |
| Color | As per customer requirements | Color difference meter |
| Density (g/cm³) | 1.3–1.5 | GB/T 4472 |
| Particle Size Distribution | Residuals ≤3.0 at 150um, ≤0.2 at 250um | GB/T 6554 |
| Non-volatile Content (%) | ≤99.4 | GB/T 6554-1986 |
| Magnetic Substance Content (%) | ≤0.002 | GB/T 2482-1986 |
| Gellation Time at 180°C (s) | ≤100s | GB/T 6554-1986 |
| Gellation Time at 200°C (s) | ≤60s | GB/T 6554-1986 |
| Gellation Time at 230°C (s) | ≤30s | GB/T 6554-1986 |
| Test Item | Technical Specification | Remarks |
|---|---|---|
| Appearance | Smooth, uniform color, no bubbles, no cracks, allows slight orange peel | Visual inspection |
| Adhesion (Grade) | 1-3 | SY/T 0315-2005 |
| Negative Electrode at 24h (mm) | ≤6.5 | SY/T 0315-2005 |
| Negative Electrode at 28d (mm) | ≤8 | SY/T 0315-2005 |
| Cross-sectional Crack Rate | 1-4 | SY/T 0315-2005 |
| Coating Surface Porosity Rate | 1-4 | SY/T 0315-2005 |
| Bending Resistance (3°) | No cracks | SY/T 0315-2005 |
| Volume Resistivity | ≤1*10¹³ | GB/T 1410 |
| Electric Strength (MV/m) | ≥30 | GB/T 1408.1 |
| Impact Resistance (1.5J at -30°) | No leakage points | SY/T 0315-2005 |
| Chemical Resistance | Qualified | SY/T 0315-2005 |
| Wear Resistance (Abrasion Method) | ≤3 | SY/T 0315-2005 |
| Salt Spray Test (1000h) | Coating shows no change | GB/T 1771-1991 |
MT SY/T 0315-2005 “Technical Specification for Single Layer Fusion Bonded Epoxy Powder Coating on Steel Pipes”
| Property | Specification | Remarks |
|---|---|---|
| Temperature | 200-230°C for 3-1.5 minutes | Medium-frequency heating recommended |
| Parameter | Specification | Notes |
|---|---|---|
| Applicable Equipment | Frictional charging spray, corona electrostatic spray | |
| Film Thickness | 250-450um | Adjustable according to workpiece requirements |
Single‑layer Fusion Bonded Epoxy (FBE) coating is a type of thermosetting epoxy powder coating used primarily for corrosion protection of steel substrates such as pipelines, fittings, and structural parts. In this process, the epoxy powder is electrostatically applied to a pre‑treated surface and then melted and fused into a continuous coating when exposed to elevated temperatures. The resulting coating forms a seamless, adherent film with excellent corrosion resistance and mechanical integrity.
The term fusion‑bonded epoxy refers to the powder transforming into a molten liquid upon contact with a heated substrate, typically between 180–250 °C, and then chemically and physically bonding to the steel surface during curing. This creates a tough, uniform protective layer without the solvents used in liquid paints. FBE coatings are thermoset polymers that cross‑link during cure, producing a dense dielectric barrier that resists moisture, chemicals, and soil stress in buried applications.
Single‑layer FBE coatings offer a set of technical advantages that make them widely used for anti‑corrosion applications:
Excellent Corrosion Resistance: The fused epoxy film effectively isolated metal from corrosive environments.
Strong Adhesion: Fusion bonding ensures robust attachment to sand‑blasted steel, reducing delamination risk.
Cathodic Disbondment Resistance: The coating resists separation under electrochemical stress.
Chemical and Solvent Resistance: The epoxy matrix withstands many industrial chemicals.
Simplicity of Application: Single‑layer FBE can be applied in one pass, saving production steps compared to multi‑layer systems.
FBE coatings are widely applied to pipeline systems and are often specified to meet common international standards such as:
ISO 21809‑2: External fusion‑bonded epoxy coatings for steel pipelines.
CAN/CSA Z245.20: External fusion‑bonded epoxy coating for steel pipes.
DIN 30670 / DIN 30671: German standards for epoxy pipeline coatings.
SY/T 0315: Chinese technical specification for single‑layer fusion bonded epoxy powder coatings for steel pipe.
These standards typically define coating thickness, adhesion, cathodic disbondment resistance, and environmental test requirements for pipeline service.
Coating thickness for single‑layer FBE systems varies based on service requirements. General minimum thicknesses often cited in standards include:
Single‑layer FBE: ~300 µm minimum for general corrosion protection
Higher thicknesses may be engineered for aggressive environments or specific pipeline classes.
Single‑layer epoxy coatings are commonly used for external protection of buried or submerged pipelines in oil, gas, and water distribution networks, providing reliable corrosion barriers where single‑coat performance is sufficient.
The general production steps for FBE single‑layer epoxy application include:
Surface Preparation — Grit blasting to Sa 2.5 or equivalent roughness standard to ensure mechanical adhesion.
Preheating — Heating the substrate (especially pipes) to the target temperature range (~200–230 °C).
Electrostatic Powder Spray — Applying the epoxy powder uniformly; because the surface is hot, the powder melts immediately upon impact.
Curing — Powder flows and cures into a continuous, bonded layer as it cools.
This process yields a one‑time film‑forming structure with excellent adhesion and membrane continuity. For spiral welded and other welded pipelines, FBE coatings typically range 300–500 µm thick.
Single‑layer FBE epoxy coatings are widely used in:
Oil and Gas Pipelines: External corrosion protection for buried and subsea segments.
Water and Sewage Systems: Protection for potable water and sewer pipelines.
Industrial Pipeline Networks: Chemical, power plant, and refinery piping.
Valves and Fittings: Corrosion‑resistant coatings for steel components in fluid systems.
The coating’s robust adhesion and corrosion resistance make it suitable for environments where direct soil contact, moisture exposure, and mechanical stresses are factors.
While single‑layer FBE offers strong corrosion protection, its characteristics include some limitations:
Mechanical Resistance: FBE coatings generally have good adhesion but moderate resistance to mechanical damage compared with multi‑layer systems.
Moisture/Heat Sensitivity: Without additional layers, resistance to heat cycling and moisture ingress is more limited than in dual‑layer or 3LPE systems.
Thickness Constraints: Single‑layer systems optimized for corrosion may not provide the same impact resistance as thicker or layered alternatives.
Recent research in the field of FBE coatings has focused on improving mechanical and anti‑corrosion performance through material science innovation. For example, nanomaterial‑modified fusion bonded epoxy resins have shown enhanced microhardness, corrosion resistance, and adhesion characteristics, demonstrating that material enhancements at the nano‑scale can further elevate FBE coating performance.
Powder coatings can be categorized by resin system (epoxy, polyester, hybrid, polyurethane), appearance (smooth, texture, hammer, metallic, pearlescent), or performance level (anti-corrosion, heat-resistant, UV-resistant, architectural grade, automotive grade).
Powder coatings offer thousands of colors in gloss, matte, satin, metallic, candy, texture, wrinkle, hammer tone, wood grain, fluorescent, and other custom effects. Special powders can create soft-touch, anti-scratch, anti-fingerprint, or anti-graffiti surfaces.
The process generally includes surface pretreatment (degreasing, phosphating, chromating, sandblasting), drying, electrostatic spraying, curing in an oven, and cooling. A well-controlled pretreatment and curing process ensures strong adhesion and long service life.
Powder coatings are environmentally friendly, solvent-free, and produce minimal waste. They offer excellent corrosion resistance, weather durability, mechanical strength, and uniform film appearance. The coating is tough, impact-resistant, scratch-resistant, and has a long lifespan.
Powder coatings are widely used in appliances, aluminum profiles, architectural components, automotive parts, bicycles, furniture, outdoor equipment, machinery, electrical cabinets, pipeline systems, and general industrial and consumer goods.
Powder coating is a dry finishing technology where finely ground powder is electrostatically sprayed onto a metal or non-metal surface and then cured at high temperature. After curing, the powder melts into a continuous, durable, and decorative coating layer.
Powder coating protects the substrate from corrosion, weathering, chemical attack, and mechanical wear. It also provides decorative appearance with rich colors, gloss levels, textures, and special effects.
In many industrial applications, powder coating outperforms liquid paint. It forms a thicker and tougher coating, resists corrosion and chemicals better, and does not contain VOCs. It also provides excellent consistency and cost-effective mass production.
It is called powder coating because the coating material is a solid powder instead of a liquid paint. The coating is formed by melting and curing powder particles under heat.
Powder coatings include several families depending on resin chemistry:
• Epoxy powders
• Polyester powders
• Epoxy-polyester hybrid powders
• Polyurethane powders
• Acrylic powders
• Fluorocarbon (PVDF) powders
Each type has its own performance features such as corrosion resistance, UV resistance, chemical resistance, outdoor durability, or decorative properties.
Powder coatings are based on thermoset or thermoplastic resins combined with pigments, curing agents, fillers, additives, and in some cases metallic or effect particles. Common substrates include steel, aluminum, galvanized metal, MDF, and certain heat-resistant plastics.
The lifespan depends on powder type, film thickness, application method, pretreatment, and service environment. Indoor coatings can last more than 10–20 years. High-grade outdoor polyester or fluorocarbon powders can last 15–25 years or longer under UV exposure.
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