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For steel pipes used in potable water transmission, a variety of coating materials are available to ensure durability, corrosion resistance, and long-term performance. Common coating types include:
Coal Tar Enamel
Cement Mortar
Liquid-Applied Epoxy
Fusion Bonded Epoxy (FBE)
Polyurethane (PU)
Each of these lining technologies offers specific advantages and limitations, making them suitable for different applications. Proper surface preparation and application techniques are essential for the effective performance of each interior coating.
What Does Epoxy Coating Mean
Epoxy coatings are made from two key components: epoxy resin and a polyamine hardener (catalyst). When combined, these elements undergo a chemical reaction that forms strong cross-links as the coating cures. Once fully cured, the epoxy transforms into a durable, rigid plastic layer with exceptional mechanical properties. Epoxy coatings are highly valued for their, Hardness and durability, Abrasion and impact resistance, Chemical resistance.
These qualities make epoxy coatings an ideal solution for protecting steel and other components in demanding industrial environments, ensuring long-lasting performance and reliability.
Epoxy floor coatings are widely used to enhance the durability of concrete floors in industrial facilities, warehouses, logistics centers, and other areas exposed to light vehicular and medium-to-heavy foot traffic. Their excellent chemical resistance—against oils, cleaners, and bleach—makes them a preferred choice in the automotive and industrial sectors.
Fusion Bonded Epoxy (FBE) coatings are extensively employed in the oil & gas, water, and wastewater industries to protect pipelines from corrosion, ensuring long-term reliability and asset protection.
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Coal Tar Enamel paint of pipe
Coal Tar Enamel (CTE) is a robust coating material derived from coal tar pitch, produced during coking operations at around 1,300°C. The addition of fillers and coal provides flexibility and strength, making CTE an ideal solution for pipeline corrosion protection.
Key advantages of CTE coatings include:
Water Resistance – Negligible water absorption and vapor transmission.
Stable Chemical Structure – Resistant to acids and alkalis.
Resistance to Cathodic Disbonding – Maintains integrity even in pipelines protected with impressed current or sacrificial anodes.
High Electrical Resistance – Electrical resistivity remains extremely high (10¹⁴ ohm·cm³) even after prolonged water exposure.
Excellent Adhesion – Forms a permanent, strong bond to steel surfaces.
Biological and Environmental Resistance – Protects against bacteria, marine organisms, and root penetration.
CTE coatings provide long-lasting protection, ensuring pipeline durability and reliability under demanding conditions.
Fusion Bonded Epoxies
Fusion Bonded Epoxies (FBE) are one-part, heat-curable, thermosetting epoxy coatings applied in powder form to heated steel surfaces. Typically applied at 10–40 mils, the powder rapidly transforms from liquid to solid, forming a tough, resilient coating with excellent adhesion. FBEs are also environmentally friendly, containing no volatile organic compounds (VOCs).
Key Application Guidelines:
FBE must be applied immediately after heating to prevent excess cooling; if the steel drops below 450°F, the coating may not fully cure.
Application is performed using semi-automated rings, electrostatic guns, or flocking units to achieve a minimum thickness of 14–16 mils.
The coating is usually applied in multiple passes of 2–5 mils to ensure uniform coverage and prevent lamination.
FBE dries to the touch within one minute and fully cures in approximately three minutes depending on the formulation.
Handling and testing can safely begin once the coated pipe cools to around 200°F.
FBE coatings provide durable, protective solutions for pipelines and steel components, ensuring long-lasting performance in demanding environments.
Polyurethane (PU) Pipe Linings
Aromatic polyurethanes are 100% solids, VOC-free coatings widely used for lining the internal surfaces of potable water pipes. Typically applied at a minimum thickness of 20 mils, thicker applications are also possible, providing robust corrosion protection and enhanced pipe performance.
Key Advantages of Polyurethane Linings:
Fast Curing – Enables high production rates and efficient operations.
Excellent Adhesion – Bonds strongly to ferrous and properly prepared steel surfaces.
High Impact Resistance – Ensures durability in demanding conditions.
Effective Corrosion Protection – Extends the service life of pipelines.
Efficient Design – Lower lining thickness reduces material wastage and increases pipeline capacity for the same pipe size.
Reduced Friction Losses – Smooth internal surfaces decrease head loss and pumping costs.
Longer Economic Life – Minimizes deterioration due to erosion and cavitation.
Polyurethane linings provide a durable, reliable, and cost-effective solution for potable water pipelines, combining superior performance with long-term efficiency.
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