Pipe Coatings: Protecting Critical Infrastructure from Corrosion
Pipe Coatings: Protecting Critical Infrastructure from Corrosion
Blog Article
Pipes are one of the most crucial components used across various industries to transport liquids and gases over long distances. Whether it is transporting oil and gas or supplying water, accurate piping infrastructure is essential for industrial and domestic needs. However, unprotected pipes are highly susceptible to corrosion from environmental factors like moisture, chemicals and microbes. This can severely compromise the integrity and performance of piping systems. To prevent corrosion and extend the functional life of pipes, advanced coating solutions are widely used. Let’s take a detailed look at various types of pipe coatings and their applications.
Epoxy Coatings for Pipes
Epoxy coatings are one of the most commonly used protective Pipe Coatings due to their excellent adhesion and corrosion resistance properties. They form a dense, impermeable barrier between the pipe material and surrounding environment. Epoxy coatings can withstand exposure to salts, acids, alkalis and other corrosive elements. They are suitable for protecting underground pipes transporting corrosive liquids. Epoxy also provides added protection to pipes in geothermal, desalination and offshore oil/gas extraction applications facing harsh conditions. Thermally sprayed epoxy and liquid epoxy coatings are applied depending on pipe size and surface requirements.
Polyurethane Coatings
Polyurethane coatings offer strong abrasion resistance and flexibility making them ideal for complex piping layouts with bends and joints. Both two-component spray and roller applied polyurethane coatings are used in the industry. They form a tough, durable film offering long-lasting protection to pipes transporting water, wastewater and slurries. Polyurethane coating is heat resistant up to 120°C, protecting process pipes in plants. The flexible coating does not crack or peel even over welds and edges. It is frequently used for rehabbing old piping infrastructure to renew protection.
Concrete Weight Coatings
Concrete weight coatings are cementitious coatings containing aggregate filler that provide corrosion protection as well as increase pipe weight per unit length. The additional weight resists buoyancy and prevents piping from floating during transportation and installation. Concrete weight coating is often applied to pipelines installed through horizontal directional drilling under bodies of water or in swampland areas. It protects the pipeline from corrosion and external impacts during backfilling. Reinforced concrete coating can withstand temperatures up to 93°C.
Fusion Bonded Epoxy Coatings
Fusion bonded epoxy (FBE) coating involves melting powder epoxy resin onto preheated pipe surfaces creating an extremely thick (200-1000 microns) and impermeable barrier coating. As the name suggests, FBE forms a metallurgical bond with the pipe material that cannot be peeled or removed. It is widely used for coating oil and gas transmission pipelines and offshore risers/flowlines. FBE coating has exceptional abrasion and corrosion resistance taking pipes to operations at -50°C to 65°C. The high-build coating provides cathodic protection to buried or immersed pipes for 30+ years.
Liquid Epoxy Coatings
Liquid epoxy coatings are applied by spray or brush and form thinner barrier coatings than FBE but offer corrosion protection for 15-25 years. They are suitable for short to medium length pipes used for water, sewage, slurry transportation. The coating cures to form a hard, dense film preventing contact with water and chemicals. Liquid epoxies adhere strongly to metal surfaces and offer UV resistance for above ground applications. The coating is flexible and withstands minor impacts and vibrations during transportation and installation. Touch-up after field weldings also extend the coating life.
Specialized Polyethylene and Polypropylene Coatings
In some non-abrasive applications requiring resistance to chemicals like acids and varying temperatures, specialized polyethylene and polypropylene coatings are used. Soft coatings like these are extruded or wrapped onto pipes. They withstand continuous operating temperatures from -50°C to 82°C. The coatings provide an impermeable barrier and do not corrode, rust or flake. They find applications in transporting chemicals, slurries, wood pulps and food products where piping debris contamination cannot be tolerated.
Coatings' Role in Infrastructure Protection
As discussed, advanced pipe coating solutions play a vital role in preserving critical piping infrastructure and delivering corrosion protection for 15-50 years depending on the type. From transportation of oil and gas to water supply, coated pipes allow for safe, efficient and reliable transfer of fluids. Pipeline operators and municipalities utilize high-performance coatings for rehabbing aging assets and extending their functional lifecycle. With proper application and inspection routines, coated pipes can outlast the designed service life of projects. This helps enable sustainable infrastructure development with lower long-term maintenance costs.
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About Author:
Ravina Pandya, Content Writer, has a strong foothold in the market research industry. She specializes in writing well-researched articles from different industries, including food and beverages, information and technology, healthcare, chemical and materials, etc. (https://www.linkedin.com/in/ravina-pandya-1a3984191)