China Aluminum Network reports that the two-layer FBE (Fusion Bonded Epoxy) coating system consists of an FBE undercoat and a modified FBE top coat, which together provide enhanced protection for bare steel tubes. The overall coating process is similar to standard FBE application, with the main difference being the arrangement of spray chambers and guns. No complex or advanced equipment is needed, making it cost-effective and easy to implement. The powder is applied using either a dual-spray chamber setup or a single integrated chamber, depending on the specific requirements of the project.
Laboratory testing and field applications have confirmed the outstanding performance of the two-layer FBE system. When used on buried steel pipelines, it exhibits strong adhesion to the substrate, excellent resistance to cathodic disbondment, low water absorption, and superior high-temperature stability. One of its most notable advantages is the combination of the strong bonding properties of standard FBE with the improved moisture resistance of the modified FBE layer. This makes it highly effective in preventing corrosion and extending the lifespan of pipelines.
With the development of new materials, the welding process at spot weld seams has become more flexible. A conventional fluidized bed system can be used, and the pipe can be heated locally using induction heating before being sprayed with FBE to cover the joint. Alternatively, specialized coatings such as Parrott Pipe anti-corrosion paint from the U.S. and ATO Super Pottery anti-corrosion paint from Korea Jingxing Industry Co., Ltd. can be applied using a cold coating method on-site. These products have been tested by pipeline companies and show strong adhesion to FBE, comparable performance, and ease of application. They are currently considered the best alternatives for spot welding areas.
In summary, the modified two-layer FBE anti-corrosion system offers performance similar to that of a three-layer coating structure but with a simpler and more efficient application process. According to partial data, over a dozen single-layer FBE production lines have been established across the country. With minor upgrades, these lines can be adapted to produce the modified two-layer FBE coating, reducing costs while maintaining or even improving performance compared to traditional three-layer systems. Additionally, it helps prevent issues like cathodic protection shielding, thereby raising the overall standard of domestic pipeline corrosion protection technology. As a result, the modified two-layer FBE system is expected to gain significant market traction in steel pipe corrosion protection projects due to its reliability, cost-effectiveness, and technical superiority.
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