Advanced Protection · 10–15 Years

Telecom Tower Anti-Corrosion Coating Process

For Industrial Pollution / Chemical Corrosion ZonesTelecom Tower,using a classic 3-CoatingSystem: XGE-HY Iron Red High-Strength Epoxy Primer + XGE-HY-B MIO Micaceous Iron Oxide Intermediate + XGE-922 Acrylic Polyurethane Topcoat (Custom Red/White Warning Bands).MIO lamellar barrier structure creates a labyrinth effect, actual service life can reach 10–15 years, compliant with ICAO aviation obstacle marking requirements.

SubstrateHot-Dip Galvanized Steel
System3-Coat System
PrimerXGE-HY · Iron Red
IntermediateXGE-HY-B · MIO
TopcoatXGE-922 · Red/White
Service Life10–15 Years
EnvironmentC4–C5 Industrial Pollution
01

System Overview

Telecom Tower (Angle-Steel Tower) Red/white aviation warning coating,3-coat total DFT ≥ 300 μm.

Warning Band XGE-921 Red Topcoat XGE-922 White Intermediate XGE-HY-B MIO Primer XGE-HY Iron Red Zn Galvanizing XGE-HY 100 μm XGE-HY-B MIO 100 μm XGE-922 White 80 μm XGE-921 Red 30 μm Warning Band Environment ~30m 0m

3-Coat System Products

HY

XGE-HY Primer

Primer · High-Strength Epoxy · Barrier + Adhesion
Color · Iron Red DFT 80–120 μm Zinc-Rich Epoxy
MIO

XGE-HY-B Intermediate

Intermediate · MIO · Labyrinth Barrier
Color · MIO Grey DFT 80–120 μm Epoxy MIO
922

XGE-922 Topcoat (Custom)

Topcoat · Acrylic Polyurethane · Red/White Warning
Color · Red/White DFT 60–80 μm Acrylic Polyurethane
HorizontalRed/White WarningBand · ICAO Marking

Total DFT

Primer
100 μm
Intermediate
100 μm
Topcoat
80 μm
Total
≥ 280 μm
02

Construction Phase Overview

3-Coat + Warning Bands,5-Stage Closed-Loop,SevereIndustrialPollutionEnvironmentExclusive.

Phase 1 · Preparation 01

SubstrateInspection

Full inspection of galvanizing, welds, gusset plates, bolts; sharp edge rounding R≥2mm.

· ISO 1461 Galvanizing · Sharp Edge R≥2mm
Phase 2 · Surface Preparation 02

Blast Cleaning Sa 2.5

Oil-free abrasive blasting, Rz 50–85 μm, uniform anchor profile.

· ISO 8501-1 Sa 2.5 · Rz 50–85 μm
Phase 3 · Primer 03

XGE-HY Primer

Iron RedEpoxyPrimer 1–2 Coats,Provides adhesion and first barrier layer.

· DFT 80–120 μm · Recoat ≥ 10h / 25°C
Phase 4 · Intermediate 04

XGE-HY-B MIO

Micaceous Iron OxideIntermediate,Lamellar structure creates"Labyrinth Effect".

· DFT 80–120 μm · Recoat ≥ 8h / 25°C
Phase 5 · Topcoat 05

XGE-922 White

Acrylic Polyurethane Topcoat 1–2 Coats,White base color.

· DFT 60–80 μm · Touch-dry 2h / Hard-dry 24h
Phase 5 · Warning 06

Red/White WarningBand

XGE-921 Red horizontal spray with tape positioning, ICAO compliant.

· Red band every 3m · Band width 200–300mm
Phase 6 · Final Inspection 07

Quality Final Inspection

Full inspection of total DFT, color difference, warning band dimensions, and adhesion.

· ΔE ≤ 1.0 · Warning band alignment ±2mm
Delivery 08

Delivery

3-Coat + Warning Bands,Protection 10–15 Years,CompliantAviation Obstacle Marking.

· ICAO Compliant · 10–15 YearsLife
03

DetailedProcess

10 key steps, 6 quality gates, with rework loops for non-conformance.

flowchart TD Start([Site Survey
Industrial Pollution / Chemical CorrosionEnvironment]) --> S1[1 · SubstrateInspection
Galvanizing + Welds + JointPlate] S1 --> Q1{QualityGate 1
GalvanizingOK?} Q1 -- No --> R1[Re-Galvanize / Edge Repair] R1 --> S1 Q1 -- Yes --> S2[2 · Surface Prep
Blast ISO Sa 2.5
Rz 50–85μm] S2 --> S3[3 · Surface Clean
Oil-Free Air + Solvent Wipe] S3 --> Q2{QualityGate 2
Cleanliness / Roughness?} Q2 -- No --> S2 Q2 -- Yes --> P1[4 · SprayPrimer XGE-HY
Iron Red · 80–120μm · 1-2 Coats] P1 --> D1[5 · PrimerDrying
25℃ × 10h] D1 --> Q3{QualityGate 3
PrimerDFT + Adhesion?} Q3 -- No --> P1 Q3 -- Yes --> M1[6 · SprayIntermediate XGE-HY-B
MIO · 80–120μm · 1-2 Coats] M1 --> D2[7 · IntermediateDrying
25℃ × 8h] D2 --> Q4{QualityGate 4
IntermediateDFT + Barrier?} Q4 -- No --> M1 Q4 -- Yes --> P2[8 · SprayTopcoat XGE-922 White
60–80μm · 1-2 Coats] P2 --> D3[9 · TopcoatDrying
25℃ × 24h · Force Cure 7d] D3 --> P3[10 · Red/White WarningBand
XGE-921 Red · 30μm
per 3m RedBand 200-300mm] P3 --> Q5{QualityGate 5
Warning BandDimensions + Alignment?} Q5 -- No --> Fix[Spot Repair] Fix --> Q5 Q5 -- Yes --> Q6{QualityGate 6
Final InspectionOK?} Q6 -- No --> Fix Q6 -- Yes --> End([Delivery · Protection 10–15 Years
IndustrialPollutionEnvironment]) classDef prep fill:#fbfaf6,stroke:#a8a39a,stroke-width:1.5px,color:#14171e classDef primer fill:#e8d0c8,stroke:#a04030,stroke-width:2px,color:#14171e classDef mio fill:#d4c8be,stroke:#6b5a4f,stroke-width:2px,color:#14171e classDef topcoat fill:#e8e8e2,stroke:#2c3138,stroke-width:2px,color:#14171e classDef warn fill:#f1dad5,stroke:#c44a3d,stroke-width:2px,color:#14171e classDef qc fill:#f3e3d0,stroke:#c97b3f,stroke-width:1.5px,color:#14171e classDef end fill:#2c3138,stroke:#2c3138,stroke-width:2px,color:#ffffff class Start,End end class S1,S2,S3 prep class P1,D1 primer class M1,D2 mio class P2,D3 topcoat class P3 warn class Q1,Q2,Q3,Q4,Q5,Q6,Fix,R1 qc
SubstratePrep
XGE-HY Iron RedPrimer
XGE-HY-B MIO Intermediate
XGE-922 WhiteTopcoat
XGE-921 Red Warning Band
Quality Gate / Repair
04

MIO Intermediate · Labyrinth Barrier Principle

Micaceous Iron OxideLamellarStructure,Moisture permeation path extended by 5–10×,YesSystem 10–15 Years Service LifeKey.

Zn Galvanizing XGE-HY Primer MIO Intermediate (Lamellar) XGE-922 WhiteTopcoat XGE-921 Red Warning Band ↑ / O₂ / Cl⁻ / SO₂ ↑ Permeation ≈ 145μm ≈ 5–10x

Why is MIO Intermediate?

inIndustrial Pollution / Chemical CorrosionEnvironmentin,moisture, O₂Cl⁻SO₂ continuouslySubstratePermeation.Ordinary 2-CoatingSystem linear permeation path of only ~ 140–180 μm,5–8 YearafterCoatingUnderCorrosionappears.

MIO Intermediate lamellarStructure changes everything:

  • Micaceous Iron OxideFlakes horizontally overlap, forming hundreds of physical barriers
  • Moisture / media permeation path is forced to detour, actual permeation distance extended 5–10×
  • MIO is chemically stable, acid/alkali/salt-spray resistant, non-consumable
  • andPrimer / TopcoatExcellent compatibility,Intercoat Adhesion ≥ 5 MPa
  • Elevates totalSystemProtectionlife from 8 Year to 10–15 Years
05

Quality Control & Key Parameters

11 hard metrics, new warning band-specific tests + cyclic salt spray.

  • Galvanizing Thickness ≥ 85 μm
  • Sharp Edge Rounding R ≥ 2 mm
  • Blast Cleanliness / Roughness Sa 2.5 · Rz 50–85 μm
  • EnvironmentTempHumidity 10–32℃ / RH ≤ 80%
  • Primer / Intermediate / Topcoat DFT 100 / 100 / 80 μm
  • Adhesion (Pull-Off) ≥ 5 MPa
  • Intercoat Adhesion ≥ 3 MPa · per layer
  • Appearance / Color ΔE ≤ 1.0 · No Sagging
  • Warning Band Size / Alignment 200–300mm · ±2mm
  • QUV Accelerated Aging 4000h · Gloss Retention ≥ 85%
  • Cyclic Salt Spray 4200h · No Blistering

ApplicationEnvironment

EnvironmentTemperature
10–32℃
Relative Humidity
≤ 80%
Dew Point Spread
≥ 5℃
Wind Speed
≤ 3 m/s

3-Coat System Thickness

Primer
100 μm
Intermediate
100 μm
Topcoat
80 μm
06

FourGradeProtectionSystemCompleteComparison

Basic / Enhanced / Advanced / Premium,EnvironmentSelect based on life requirements etc.Grade.

Basic

10-15 Year
Structure2-Coat
TopcoatXGE-921
ResinPolyurethane
Total DFT≥ 140 μm
EnvironmentC3 / Moderate
Salt Spray500h
ApplicationTelecom Tower

Enhanced

10-15 Year
Structure2-Coat
TopcoatXGE-922
ResinAcrylic PU
Total DFT≥ 180 μm
EnvironmentC3-C4 Coastal
Salt Spray1000h
ApplicationTelecom / Wind
Recommended

Advanced

10–15 Year
Structure3-Coat + Warning
TopcoatXGE-922 Red/White
IntermediateMIO
Total DFT≥ 280 μm
EnvironmentC4 Industrial Pollution
Salt Spray4200h Cyclic
ApplicationTelecom Tower + Aviation

Premium

10-15 Year
Structure2-Coat
TopcoatXGE-930 Silver White
ResinFEVE Fluorocarbon
Total DFT≥ 220 μm
EnvironmentC4-C5 Severe
Salt Spray3000h
ApplicationPower Tower / Marine
07

Key Application Notes

Industrial Pollution / Chemical Corrosion + ICAO AviationWarningCoating specificItemsPoints.

Industrial Pollution / Chemical CorrosionEnvironment

  • Near chemical plants, smelters, coal-fired power plants,High SO₂ / H₂S / NOx concentration,MIO Intermediateessential.
  • PrimerandIntermediatestrict recoat interval between ≥ 8h / 25℃,Avoid interlayer solvent entrapment.
  • MIO IntermediateSprayafterMaintain uniform"Horizontal Texture",Mica flake orientation should be generally consistent.
  • Create full-tower DFT distribution map, min 3 test points per 5m height interval, document and archive.
  • High-altitude inspection every 2 years; focus on cross-arms, gusset plates, tower base, and critical joints.

Red/White WarningBand / ICAO AviationMarking

  • Compliant with ICAO Annex 14: towers ≥ 45m must have red/white alternating warning bands.
  • Each red band width 200–300mm, white band width 200–300mm, horizontal spray alignment ±2mm.
  • Use dedicated masking tape for positioning; moderate tack, no edge peeling after removal.
  • Warning BandandTopcoatbetweenRecommend applying XGE-921 Red base coat,Enhance color saturation and fastness.
  • Top 3 sections and bottom 3 sections are mandatory warning zones; middle sections per requirement.