Basic Protection · 3-5 Years

Telecom Tower Anti-Corrosion Coating Process

Standard coating system for galvanized telecom towers in mild to moderate environments,Using XGE-920 Grey Primer Grey Primer + XGE-921 Red Topcoat Red Topcoat Builds a two-coat protective system. XGE-920 Grey Primer provides excellent adhesion to galvanized surfaces, XGE-921 Red Topcoat delivers both aesthetics and long-term protection.。

SubstrateHot-Dip Galvanized Steel
SystemTwo-Coat (2-Coat)
PrimerXGE-920 Grey Primer · Grey
TopcoatXGE-921 Red Topcoat · Red
Service Life3 – 5 years
EnvironmentC3 / Moderate
01

System Overview

Standard telecom tower angle-steel structure, showing coating layers bottom-to-top。

Topcoat XGE-921 Red Topcoat Red · 50–70 μm Primer XGE-920 Grey Primer Grey · 60–80 μm Hot-DipGalvanized Substrate Zn XGE-920 Grey Primer · 80μm XGE-921 Red Topcoat · 60μm Air ~30m 0m

Coating Products

920

XGE-920 Grey Primer Primer

Primer · Excellent adhesion to galvanized surfaces
Color · Grey Dry Film 60–80 μm Epoxy / Acrylic
921

XGE-921 Red Topcoat Topcoat

Topcoat · Decorative + UV / Chemical Resistant
Color · Red Dry Film 50–70 μm Polyurethane

Total Dry Film Thickness

Primer
80 μm
Topcoat
60 μm
Total
≥ 140 μm
02

Application Phase Overview

From substrate inspection to product delivery, managed in four closed-loop phases。

Phase 1 · Prep 01

Substrate Inspection

Verify galvanized layer integrity, free of white rust and oil, record substrate condition。

· ISO 1461 Galvanized · Surface Cleanliness ≤ Grade 2
Phase 2 · Surface Preparation 02

Sanding & Clean

Light sweep blasting / manual sanding to remove zinc salts, solvent wipe followed by dust-off。

· Tool: Wire Brush / P120 · Compressed Air: Oil-free, Water-free
Phase 3 · Primer 03

Application XGE-920 Grey Primer

Airless Spray 1–2 coat, wet film ~120 μm,RecommendedGrey Primer。

· DFT 60–80 μm · Recoat Interval ≥ 6h / 25℃
Phase 3 · Topcoat 04

Application XGE-921 Red Topcoat

Airless / Conventional Spray 1–2 coats, achieve RAL 3020 Red finish。

· DFT 50–70 μm · Touch-dry 2h / Hard-dry 24h
03

DetailProcess

8 key steps with quality gate checkpoints, rejects return to rework。

flowchart TD Start([Site Survey
Telecom TowerGalvanized Substrate]) --> S1[1 · Substrate Inspection
Galvanized Layer Integrity] S1 --> Q1{Quality Gate 1
GalvanizedCoatsPASS?} Q1 -- No --> R1[Zinc Removal / Re-galvanize
Rework] R1 --> S1 Q1 -- Yes --> S2[2 · Surface Preparation
Sweep Blast + Solvent Wipe] S2 --> S3[3 · Surface Cleaning
Oil-free Compressed Air Dust-off] S3 --> Q2{Quality Gate 2
Clean°PASS?} Q2 -- No --> S2 Q2 -- Yes --> P1[4 · SprayPrimer XGE-920 Grey Primer
Grey · 60–80 μm] P1 --> D1[5 · Primer Drying
25℃ × 6h] D1 --> Q3{Quality Gate 3
PrimerDFT OK??} Q3 -- No --> P1 Q3 -- Yes --> P2[6 · SprayTopcoat XGE-921 Red Topcoat
Red · 50–70 μm] P2 --> D2[7 · TopcoatDrying
25℃ × 24h] D2 --> Q4{Quality Gate 4
Final CheckPASS?} Q4 -- No --> Fix[Local Touch-up / Rework] Fix --> Q4 Q4 -- Yes --> End([Delivery · 3-5 Year Protection]) classDef prep fill:#fbfaf6,stroke:#a8a39a,stroke-width:1.5px,color:#14171e classDef primer fill:#dcdde0,stroke:#6f7177,stroke-width:1.5px,color:#14171e classDef topcoat fill:#f1dad5,stroke:#b1372a,stroke-width:2px,color:#14171e classDef qc fill:#f3e3d0,stroke:#c97b3f,stroke-width:1.5px,color:#14171e classDef end fill:#b1372a,stroke:#b1372a,stroke-width:2px,color:#ffffff class Start,End end class S1,S2,S3 prep class P1,D1 primer class P2,D2 topcoat class Q1,Q2,Q3,Q4,Fix qc
Substrate Treatment
XGE-920 Grey Primer Primer
XGE-921 Red Topcoat Red Topcoat
Quality Gate / Repair
04

Quality Control & Key Parameters

Inspection items and acceptance criteria for each quality gate checkpoint。

  • Galvanized Layer Thickness ≥ 85 μm
  • Surface Cleanliness ISO 8501-1 ≤ 2 Grade
  • Ambient Temp / Humidity 5–35℃ / RH ≤ 85%
  • Primer DFT 60–80 μm
  • Topcoat DFT 50–70 μm
  • Adhesion (Cross-cut) ASTM Grade 0–1
  • Appearance / Color RAL 3020 · No sagging

Application Conditions

Ambient Temperature
5–35℃
Relative Humidity
≤ 85%
Dew Point Margin
≥ 3℃
Wind Speed
≤ 5 m/s

Total Coating Thickness

Primer
80 μm
Topcoat
60 μm
05

Key Application Notes

Standard practice for galvanized substrates to extend system service life.

Galvanized Surface Key Points

  • New galvanized surfaces should weather naturally for 4–6 weeks, or apply primer immediately after sweep blasting.
  • White rust / zinc salts must be completely removed, otherwise primer adhesion will be significantly reduced.
  • Airless spray pressure 15–20 MPa, 50% fan pattern overlap.
  • Ensure primer is fully dry before recoating to prevent solvent entrapment and topcoat blistering.
  • Pre-coat dead corners (tower base, bolts, gusset plates) by brush before overall spray.