Corrosion and exposure to external contaminants like toxic substances and chemicals can cause pipes to experience a significant loss due to physical damage, reduced productivity, increased replacement components and higher maintenance costs. This is where a protective external pipe coating comes in. When you apply a coating to a pipe, you can decrease these losses to your bottom line. A coating creates a barrier between external environments and metal pipes. A protective layer of coating is essential in industries like construction and aerospace manufacturing.
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This guide covers various metal pipe coating types, defines different types of coatings and can help you determine the kind of pipe or tube coating machine you need.
When steel is produced, it starts to oxidize again to its initial state of iron oxide. Metal and steel pipes are vulnerable to abrasions, acidic elements, electric currents and corrosion by moisture or air. These can all lead to disasters like a pipe leak or a steel wall explosion. A protective coating forms a barrier between the surface of the steel and oxygen, which can cause oxidation. Pipes properly treated with coating can benefit from additional protection against corrosion and extended life spans.
External pipe coatings help preserve the metal pipes you work with and ensure their durability. Pipe coatings make pipes stronger and more effective at transporting water, gases and oils. Along with protecting and safeguarding the pipe, metal and steel pipe coatings can mean pipes require less maintenance. Because of all these benefits, there is high demand for good quality pipe coatings.
Metal coating machine manufacturers produce equipment to create different types of coatings. Processes for applying coatings to steel and metal parts include:
Each technique addresses different environments and uses. Aluminum, zinc, lead or powdered stainless steel can pigment coatings. Coated pipes appear clean and smooth, making them look attractive and hygienic.
There are three main types of external pipeline coatings — solvent-borne coatings, water-borne coatings and UV coatings. The type of coating that is right for your project depends on the specific circumstances of the job. Each type of coating has its advantages, and they perform differently depending on the situation and conditions.
Sometimes known as solvent-based coatings, solvent-borne coatings are liquid protective layers mainly composed of organic compounds added to the surface of a material to prevent corrosion. Typically, these coatings are more resilient than a water-borne coating. Solvent-borne coatings tend to be better suited to applications in humid environments that prevent water-borne coatings from curing properly.
These coatings cure because of a chemical reaction between the coating and oxygen rather than by water evaporation, which means humidity is less of a factor for this type of coating. However, solvent-borne coatings are also considered less environmentally friendly than water-borne coatings because they often contain volatile organic compounds (VOCs).
Still, solvent-borne coatings are popular for use in harsh conditions. These coatings are less vulnerable to environmental conditions like humidity and temperature during the curing phase, so they are practical in nearly any climate. Other advantages of solvent-borne coatings include:
Water-borne or water-based coatings are another type of pipe coating. Advances in water-borne coatings make it an attractive option for protecting material surfaces. Benefits of a water-borne coating include ease of thinning, lower VOCs and low toxicity. Water-borne coatings have quick drying times and excellent adhesion properties. These coatings can be applied with several different methods, such as flood and wipe, dip and spray.
For workers, evaporation of solvents may be uncomfortable and even hazardous while working in poorly ventilated or confined spaces. As a result, projects that involve railroad tankards and fuel storage tanks use water-based coatings. Water-borne coatings can also lower the concentration of flammable materials in a confined space.
Another one of the major advantages of a water-borne coating is environmental compliance. Many solvents evaporate into VOCs. State, local and national governments often regulate the amount of VOCs businesses are permitted to emit during a certain time. However, water can also be a key component in the corrosion process. Spot rusting could occur if the water comes in contact with the substrate before applying the coating. To prevent this, water-borne coatings should be formulated to draw out the water through a surface film.
Another type of pipe coating is UV, which is photoreactive and instantaneously polymerized when exposed to UV radiation. Typically, the coating cure rate varies depending on the power of the light source, such as how long the coating is exposed to the light and the amount of oxygen in the chamber, as oxygen inhibits surface cure. A UV coating can be applied with flood and wipe equipment or conventional spray. Advantages of a UV coating include:
However, there are also a few disadvantages of UV coatings. This coating tends to be more expensive than other coatings and can sometimes give off a strong odor. Due to the need for replacement UV bulbs, these coatings can come with higher equipment maintenance costs. The UV coating process can also be hazardous, causing sunburn and allergies. With the Dubois Pipe Coater, you can apply 100% solid UV coating to tubes or pipes.
Now that you’re familiar with the three main types of pipe coatings, it’s important to know the specific type of coating you need, as your choice of machine will depend on it.
HPPC is a commonly used coating material in many types of industries. This coating contains a polymer resin combination, including additives, colorants and flow modifiers. HPPC is suitable for pipes in extreme or harsh environmental conditions, such as gas and oil pipelines and metal refineries.
HPPC includes a compound polyethylene to protect pipes during an underground project or transport. The polyethylene component helps maintain the pipe’s quality even when exposed to soils and chemicals. HPPC coatings are best for pipes with smaller circumferences and may not be appropriate for pipes used in construction projects.
Pipes coated with 3LPE or 3LPP include three layers of coating:
The final layer provides durable, tough protection against erosions and corrosion. A 3PLE or 3LPP coating can strengthen a pipe’s electrical resistance, mechanical properties and anti-aging qualities. This coating can also make a pipe waterproof and protect it from heat loss. This means a 3PLE or 3LPP coating offers the advantages of FBE and polyethylene or polypropylene. Benefits of these pipe coating types include:
There are also some disadvantages to these pipe coating types, such as:
HDTLPC combines adhesive layers and powder and contains polyethylene content similar to HPPC. HDTLPC is the final coat on a multi-layered coating. Typical powder and two-layer coatings peel off easily. HDTLPC is more durable and lasts longer. With HDTLPC, steel pipes can maintain their physical shape and form during storage or stacking.
Polypropylene is suitable for deep-sea applications, as these applications have high pressures and temperatures. Polypropylene coatings offer reliability, low water absorption, a high melting point, flexible coating designs and easy, stable processing. Remember that polypropylene is vulnerable to chain degradation due to exposure to UV radiation and heat and may not be the best coating for pipes regularly exposed to direct sunlight.
Another type of pipe coating is fusion-bonded epoxy (FBE). Also referred to as fusion bonding, this coating involves applying heat to a powder coating made from hardening agents and an epoxy-based resin. FBE can be bonded to steel pipe electrostatically via a heating process due to the resin’s thermosetting properties. This makes the coating longer-lasting and more effective.
One of the most efficient application methods involves submerging the preheated material in a fluidized bed for a set amount of time. This helps you achieve the coating thickness you prefer. External and internal surfaces can both be treated with FBE. FBE coatings are commonly used in the following industries and applications:
FBE can be used on pipes that are smaller in diameter and size. An FBE coating offers excellent chemical resistance and dimensional stability with minimal hysteresis. The FBE coating is more resistant to higher temperatures than other types of coating, like HPPC. This coating provides pipelines with long-term corrosion resistance. As a result, FBE is a common coating applied to steel pipes to increase their longevity.
While an FBE coating is durable and effective, it may fail in certain conditions. This coating is best suited to mild environments, as the coating can break down in temperatures that are too high or too low. The materials and application costs for an FBE coating can be more expensive per meter. There can also be long lead times.
Galvanizing is a process that prevents rusting through the application of a zinc coating to a steel pipe. Hot-dip galvanizing is one of the most common application methods and is popular among steel pipe coating machine manufacturers. If a thinner layer is required, you can opt for a galvanizing application method known as electrogalvanizing. This process involves electroplating, which is when an electric current runs through the zinc solution with a steel conductor and zinc anode.
Galvanizing can protect steel pipes by preventing the underlying steel from being affected by corrosive substances. The pipe will remain protected even when the underlying metal is exposed, as long as the zinc can be electrically coupled. The steel pipe will experience localized corrosion only if all of the zinc is consumed. This is why galvanized steel pipe is ideal for locations and applications where rust can be a problem, such as pipe systems exposed to water. Examples include water transport systems, HVAC systems and plumbing.
When choosing between pipe coating materials suppliers, you should know what to look for in a coating machine:
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When you choose a coating machine from Dubois Equipment, you can enjoy all of these benefits of pipe coating equipment. Our products are also incredibly flexible, and the high-quality materials we use in every product ensure you can rely on a machine for years.
As a pipe coating materials company, Dubois Equipment understands the pipe coating process and can supply you with the finishing equipment you need. Our customized material finishing systems are made in the U.S. and include curing ovens, sanding machines and coating machines. We can customize finishing systems for wood, metal and specialty applications and design entire finishing lines or a single machine. With more than 50 years of experience, our team of highly skilled engineers can develop and manufacture complete solutions that meet your finishing needs.
Pipeline coatings are key to protecting pipelines, which are essential for transporting energy and materials. This guide explains the different types of pipeline coating, how they're applied, and the standards they meet. It highlights how crucial these coatings are in preventing corrosion and keeping pipelines working smoothly.
Pipeline coatings serve a critical role by acting as a protective shield for both the internal and external surfaces of pipes. Pipeline coatings are pivotal in safeguarding the pipe from corrosion and environmental wear by ensuring they remain operational under various harsh conditions. Their application is key to preserving the pipe's structural integrity and ensuring its functional longevity.
The selection of a pipeline coating depends on the environmental conditions, the material transported, and the service life required. Common types include:
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FBE is a robust, thermoset polymer coating that is known for its strong adhesion and resistance to chemical and physical degradation. It's applied in a powder form and cures under heat to form a protective layer, which is ideal for environments that require high durability and corrosion resistance.
3LPE/3LPP coatings consist of three layers: a high-performance FBE base, a copolymer adhesive, and a top layer of polyethylene/propylene. These coatings are lauded for their excellent corrosion resistance, mechanical protection, and ability to withstand various environmental conditions.
CTE is a thermoplastic coating that has been used for decades due to its low cost and effective protection against corrosion. It involves applying multiple layers, including a primer, the coal tar enamel, and glass fiber wraps, that provide a durable barrier against external elements.
Polyguard's innovative approach to pipeline coatings is embodied in their geotextile-backed non-shielding anti-corrosion coatings, such as the RD-6® and RD-6 HT® systems. These products represent a significant advancement in pipeline protection technology, and are designed to address the rigorous demands of buried and submerged pipeline environments.
In protecting pipelines, it's crucial to choose the best coating system for long-lasting durability, efficiency, and being eco-friendly. Comparing Fusion-Bonded Epoxy (FBE), Three-Layer Polyethylene/Propylene (3LPE/3LPP), Coal Tar Enamel (CTE), and Polyguard's Geotextile-Backed Non-Shielding Anti-Corrosion Coatings highlights a range of options. Each offers unique advantages and uses.
FBE coatings stand out for their strong adhesion and excellent chemical resistance, which makes them suitable for harsh environments. They provide a solid, impermeable barrier that prevents corrosion and withstands high temperatures.
3LPE/3LPP systems offer superior mechanical protection and are renowned for their ability to resist environmental challenges. These coatings combine the toughness of FBE with the flexibility and impact resistance of polyethylene or polypropylene layers to provide comprehensive protection against corrosion.
CTE is known for its cost-effectiveness and long history of providing reliable corrosion protection. This system uses multiple layers, including a primer and glass fiber wraps, to create a robust barrier against environmental and chemical aggressors.
Polyguard RD-6® and RD-6 HT® coatings are distinct in their approach that offers a geotextile-backed, non-shielding system that provides strong adhesion, high breaking strength, and low elongation. These coating systems are particularly effective in mitigating soil stress and accommodating the thermal dynamics of pipelines, which makes them suitable for high-temperature applications and ensuring long-term corrosion protection.
When choosing the best coating system, it's important to look at factors such as how well it can handle the temperature, impacts, penetration, soil stress, its environmental impact, and the specific needs of the pipeline project. Each type of coating has its own advantages, and the choice usually depends on the particular conditions of the pipeline's surroundings and how long and how well you want it protected.
Pipeline coating standards, such as ISO , API RP 5L2, and NACE specifications, set the benchmark for quality and durability in the industry. These guidelines dictate the materials, application processes, and testing methods to ensure coatings meet safety and performance criteria. In real-world applications, compliance with these standards is critical for maintaining pipeline integrity and operational efficiency.
They drive innovation, pushing manufacturers to develop advanced coating technologies that not only adhere to stringent requirements, but also offer enhanced protection against corrosion and environmental wear. This constant evolution in coating technology helps the industry tackle new challenges to help ensure that pipelines are safer and more reliable.
The procedure for applying pipeline coatings involves multiple steps:
1. Surface Preparation: Clean and profile the pipe surface to ensure coating adhesion.
2. Application: Techniques vary from spray application to electrostatic methods, depending on the coating type.
3. Curing: Make sure that the coating has properly adhered and set in order to form a durable protective layer.
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In pipeline construction, it's crucial to include coating processes to make sure pipelines last longer and are more durable. It isn't just about putting on a protective layer. It involves carefully planned steps during construction to make the coating work best and improve the pipeline's performance overall.
Coating application should be timed to coincide with specific construction phases to avoid environmental or mechanical damage. For example, coatings should be applied after the pipeline has been welded and tested for defects, but before it is buried. This sequence minimizes the risk of coating damage during trenching and backfilling operations.
The environmental conditions under which coatings are applied can significantly affect their adhesion and curing processes. Optimal conditions such as temperature, humidity, and cleanliness must be maintained to ensure the coating adheres properly to the pipeline surface and cures effectively. For instance, applying coatings during extreme temperatures or high humidity levels can compromise their protective properties.
Choosing the right coating involves considering the pipeline's operational environment, the transported material, and the expected lifespan. The coating material must be compatible with the pipeline's substrate and the external conditions to prevent failures like coating delamination or corrosion under insulation (CUI).
Quality control measures and regular inspections are critical during the coating application process. Techniques such as holiday detection are employed to identify and rectify any discontinuities or defects in the coating to help ensure a continuous protective barrier.
By carefully managing these factors, using coating processes in pipeline construction improves the coatings' protective features, which greatly helps the pipeline's integrity and efficiency. This thoughtful approach is key to preventing corrosion and lengthening the pipeline's lifespan.
Pipeline coatings are the first line of defense against corrosion, a major cause of pipeline deterioration. By providing a barrier between the pipe material and corrosive elements, coatings can significantly extend the operational life of pipelines.
Polyguard specializes in innovative pipeline coating solutions that are designed to meet industry needs. With a focus on research and development, Polyguard offers coatings that ensure durability, efficiency, and protection against harsh environmental factors.
Polyguard's advanced pipeline coating systems, developed through years of research and technological innovation, meet the modern pipeline industry's needs. Our systems do more than just prevent corrosion; they provide a complete protective solution that maintains the structural integrity, efficiency, and durability of pipelines.
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