Premium Protection · 8-10 Years

Power Tower Anti-Corrosion Coating Process

For Severe Industrial / Marine / Tropical transmission tower environments, with XGE-HY Iron Red High-Strength Epoxy Primer + XGE-930 Silver White Fluorocarbon Topcoat Builds a high-performance 2-coat system. Mimics fresh hot-dip galvanized metallic finish, long-term UV / salt-spray / industrial atmosphere resistance, extending service life to 8–10 years.

SubstrateHot-Dip Galvanized Steel
System2-Coat System
PrimerXGE-HY · Iron Red
TopcoatXGE-930 · Silver White
Service Life8–10 Years
EnvironmentC4–C5 / Industrial / Marine / Tropical
01

System Overview

Typical cat-head transmission tower · XGE-930 Silver White TopcoatMimics fresh hot-dip galvanized metallic finish.

Topcoat XGE-930 Silver · 80–120 μm Primer XGE-HY Iron Red · 100–150 μm Hot-Dip GalvanizedSubstrate Zn (Galvanizing) XGE-HY 120 μm XGE-930 100 μm NaCl UV Salt Spray ~40m 0m

Coating Products

HY

XGE-HY Primer

Primer · High-Strength Epoxy · Industrial-Grade Adhesion
Color · Iron Red DFT 100–150 μm Zinc-Rich Epoxy
930

XGE-930 Topcoat (Silver White)

Topcoat · Fluorocarbon / High-Weatherability · Galvanized Appearance
Color · Silver White DFT 80–120 μm FEVE Fluorocarbon
Adjustable Metallic Finish

Total DFT

Primer
120 μm
Topcoat
100 μm
Total
≥ 220 μm
02

Construction Phase Overview

ForPower TowerFor large-scale components andJointComplex,5-stage closed-loop quality control.

Phase 1 · Preparation 01

SubstrateInspection

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

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

Blast Cleaning Sa 3.0

Oil-free abrasive blasting to near-white, Rz 60–100 μm, visible metallic luster.

· ISO 8501-1 Sa 3.0 · Rz 60–100 μm
Phase 3 · Primer Coat 03

Apply XGE-HY

Iron red epoxy primer, airless spray 2 coats, atomization pressure 18–22 MPa.

· DFT 100–150 μm · Recoat interval ≥ 12h / 25°C
Phase 4 · Topcoat 04

Apply XGE-930

Silver white fluorocarbon topcoat, airless spray 2 coats, mimics HDG metallic finish.

· DFT 80–120 μm · Force cure 14d / 25°C
03

DetailedProcess

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

flowchart TD Start([Site Survey
Severe Industrial / Marine / TropicalEnvironment]) --> S1[1 · SubstrateInspection
Galvanizing + Welds + Joint + Tower Base] S1 --> Q1{QualityGate 1
GalvanizingOK?} Q1 -- No --> R1[Re-Galvanize / Edge Repair] R1 --> S1 Q1 -- Yes --> S2[2 · Surface Preparation
Blast ISO Sa 3.0
Rz 60–100μm] S2 --> S3[3 · SurfaceClean
oil-free compressed air + Solvent Wipe] S3 --> Q2{QualityGate 2
Cleanliness / Roughness?} Q2 -- No --> S2 Q2 -- Yes --> P1[4 · SprayPrimer XGE-HY
Iron Red · 100–150μm · 2 ] P1 --> D1[5 · PrimerDrying
25℃ × 12h · Forced Ventilation] D1 --> Q3{QualityGate 3
PrimerDFT + Adhesion?} Q3 -- No --> P1 Q3 -- Yes --> P2[6 · SprayTopcoat XGE-930
Silver White · 80–120μm · 2 ] P2 --> D2[7 · TopcoatDrying
25℃ × 24h · Force Cure 14d] D2 --> Q4{QualityGate 4
DFT + Gloss + Color?} Q4 -- No --> Fix[Spot Repair] Fix --> Q4 Q4 -- Yes --> S4[8 · SiteRepair
Joint / Bolts / Welds / Tower Base] S4 --> S5[9 · Full Re-Inspection
Salt Spray / Aging / AdhesionRetest] S5 --> Q5{QualityGate 5
AcceleratedAgingOK?} Q5 -- No --> S4 Q5 -- Yes --> End([Delivery · 8-10 Year Protection
Industrial / Marine / Tropical]) classDef prep fill:#fbfaf6,stroke:#a8a39a,stroke-width:1.5px,color:#14171e classDef primer fill:#e8d0c8,stroke:#a04030,stroke-width:2px,color:#14171e classDef topcoat fill:#dde0e3,stroke:#4a4d52,stroke-width:2px,color:#14171e classDef qc fill:#f3e3d0,stroke:#c97b3f,stroke-width:1.5px,color:#14171e classDef end fill:#4a4d52,stroke:#4a4d52,stroke-width:2px,color:#ffffff class Start,End end class S1,S2,S3,S4,S5 prep class P1,D1 primer class P2,D2 topcoat class Q1,Q2,Q3,Q4,Q5,Fix qc
SubstratePrep
XGE-HY Iron Red Primer
XGE-930 Silver White Topcoat
Quality Gate / Repair
04

Quality Control & Key Parameters

Premium-grade QC, 4 additional Premium tests, 11 total inspection items.

  • Galvanizing Thickness ≥ 85 μm
  • Sharp Edge Rounding R ≥ 2 mm
  • Blast Cleanliness / Roughness Sa 3.0 · Rz 60–100 μm
  • EnvironmentHumidity 15–30℃ / RH ≤ 75%
  • Primer DFT 100–150 μm
  • Topcoat DFT 80–120 μm
  • Adhesion (Pull-Off) ≥ 5 MPa
  • Gloss (60°) ≥ 90 GU · Mirror Grade
  • Color Difference (ΔE) ≤ 0.5 · Silver White Metallic
  • QUV Accelerated Aging 3000h · Gloss Retention ≥ 85%
  • Neutral Salt Spray 3000h · Single-Side Creep ≤ 2mm

ApplicationEnvironment

EnvironmentTemperature
15–30℃
Relative Humidity
≤ 75%
Dew Point Spread
≥ 7℃
Wind Speed
≤ 2 m/s

Total Coating Thickness

Primer
120 μm
Topcoat
100 μm
05

GradeProtectionSystemComparison

Basic / Enhanced / Premium,EnvironmentSelect based on environment and life requirementsForGrade.

Basic

8-10 Year Protection
TopcoatXGE-921 Red
ResinPolyurethane
Surface PreparationSweep Blast
Total DFT≥ 140 μm
EnvironmentC3 / Moderate
Salt Spray500h
ApplicationTelecom Tower

Enhanced

8-10 Year Protection
TopcoatXGE-922 Custom
ResinAcrylicPolyurethane
Surface PreparationSa 2.5
Total DFT≥ 180 μm
EnvironmentC3-C4 / Coastal
Salt Spray1000h
ApplicationTelecom / Wind Power
Recommended

Premium

8-10 Year Protection
TopcoatXGE-930 Silver
ResinFEVE Fluorocarbon
Surface PreparationSa 3.0
Total DFT≥ 220 μm
EnvironmentC4-C5 Severe
Salt Spray3000h
ApplicationPower Tower / Marine
06

Key Application Notes

Marine / Tropical / IndustrialEnvironmentItemsControlPoints,Ensure 8-10 year service life under severe conditions.

Marine / Salt SprayEnvironment

  • Within 500m of coast or offshore platforms,Execute 3000h NeutralSalt Spray + 1000h CyclicSalt Spray.
  • Welds, tower base, gusset plates: Dual protection with primer atomized spray + topcoat pre-brush.
  • No application in Force 5 wind, rain, or fog;Dew Point Spread ≥ 7℃ before spraying.
  • Apply an additional edge-seal coat within 3m of tower base against splash / mud corrosion.

Tropical / High-TempHigh-HumidityEnvironment

  • XGE-930 FEVE FluorocarbonTopcoat 120℃,Withstands tropical ground radiation and conductor heat transfer.
  • Avoid midday peak sun; preferred spray windows: 6:00–10:00 / 16:00–19:00.
  • No contact with acid rain, bird droppings, or plant debris before full topcoat cure (≥ 14d).
  • High-altitude inspection every 2 years; focus on cross-arms / insulator bolts and critical joints.

IndustrialAtmosphere / ChemicalCorrosionEnvironment

  • Near chemical/smelting plants with high SO₂ / H₂S,Recommended XGE-HY Zinc-RichPrimerProvides cathodic protection.
  • Primer applied via atomized spray + roller composite process for full complex joint coverage.
  • Create full-tower coating thickness distribution map, min 3 test points per 5m height interval.
  • Recommend every 3 Yearspot inspection everyRepair,ExtendSystemto 15 Yearmaximum service life.