Fusion bonded epoxy coatings have been in use since the 1960s. Continuous improvements on the technology have made fusion bonded epoxy (FBE) a popular choice in coating technology across a wide variety of applications. Most commonly, FBE coatings are used to protect pipelines that carry petroleum and natural gas. Fusion bonded epoxy coatings, like all pipeline coatings, have a common purpose: protecting the pipeline material from corrosion, which is accelerated in these types of warm, wet, and abrasive environments.

The process behind the actual application of a fusion bonded epoxy coating may not be universally understood, but it does provide an interesting insight into the coating technology that benefits us every day – protecting the pipelines that deliver our energy resources and clean water.

The application process of a fusion bonded epoxy coating is multi-faceted. Before any coating is applied, the pipeline surface must be “prepared” by abrasive blasting techniques to remove all rust, grease, and other surface contaminants.  Not only will this create a clean surface for which the powder is applied, but also it will also create varying anchor patterns which will interlock the cured powder to the metal.

The powder coating process has steadily gained in popularity since its introduction in the 1960s, with coating distributors and manufacturers popping up along with service shops that perform the actual coating process. It’s clear that powder coating in Houston is an effective process, and a popular one given the presence of heavy industry nearby that can always find a use for the technology. But what exactly happens in the powder coating process?

At its heart, powder coating is a process for applying a finish that protects a wide variety of surfaces from damage, whether chemical, radioactive, or physical. In Houston and surrounding areas like the Woodlands, Katy, and Baytown, powder coating enjoys popularity due to the needs of the ever-present oil and gas industry, but it can also be used to apply a protective coating to something as basic as household appliances.

The material applied to a surface in powder coating consists of a polymer resin base combined with additional materials such as curatives, pigments, and flow modifiers. These ingredients are ground into a uniform powder before being applied to the surface to be coated with the use of a specially-made spray gun, sometimes called a corona gun. These guns use an electrostatic process to actually apply the coating, which differs significantly from other coatings, like the wet coating of a traditional paint. Since the electrostatic process eliminates the need for wet coating, powder coating in the Woodlands, TX can be helpful in protecting everything from large machinery to the miles and miles of piping used in the oil and gas industry.

When it comes to powder coat repair, the simple answer is that it isn’t that simple.

Powder coating inherently involves an oven that allows for polymers and resins to melt, cross-link, and harden to become an integrated shell for a metal component. Therefore, unless the damaged pieces can be put through this fusion-bonded process again, any other “repair” will have limited protective qualities. Houston Powder Coaters has an experienced team capable of performing multiple services related to powder coating in Houston, including powder coat repair. Although there are a few exceptions to this rule (like ones that involve thermoplastic polymers), most powder coat repair falls within the following techniques.

• Wet Paint Touch-Up – Like it sounds, wet paint can be applied by spray, brush, or roll-on methods to touch-up damaged areas. HOWEVER, it is important to note that proper surface preparation and masking are mandatory for any true level of success in the powder coat repair All damaged areas need to be sanded down and smoothed over to ensure a clean surface from which to paint.  After masking pieces to prevent any overspray or drips, a double coating of a liquid epoxy (with drying and sanding in between) will assist with sealing the damaged areas.

• Blast / Hand-Etch and Reapply – If the damage of the powder coat is limited or over a small area, the pieces can be rerun. This involves bringing the piece back to the facility where it can be ground smooth, re-blasted, and re-shot. As the anchor pattern of the previous coating is strong, the additional blast creates a new anchor pattern for the new powder to adhere to. Again, these pieces will be placed in an oven to cure. Due to the extraordinary properties of the powder polymers, enhanced “bake windows” allow for previously cured powders to be reheated without incurring damage.

• Burn-Off and Start Over – If the damage to the coating is significant, it is recommended to start from scratch. Pieces will need to be “thermal-stripped,” which means that the coating must be burnt off.  Whereas wet coatings can be removed simply with abrasive blasting techniques, powder coating must be heated up to break its physical and chemical bonds.  Afterwards, the pieces are blasted and coated as if they were untreated.

If you have any additional questions regarding powder coating in Houston or powder coat repair in general, please give Houston Powder Coaters a call.  We are happy to educate and assist.

When it comes to protecting surfaces against corrosion and enhancing durability, fusion bonded epoxy (FBE) coating has emerged as a popular choice in the city of Houston. Fusion bonded epoxy is a thermosetting powder coating that is commonly used as a protective coating for steel and other metal objects. It is applied to the surface of the material in a powder form and then heated, causing the powder to melt and fuse with the metal substrate, creating a strong and corrosion-resistant barrier.

Applications of Fusion Bonded Epoxy

The versatility of fusion bonded epoxy makes it suitable for a wide range of applications in Houston. Here are some of the key uses of FBE coating:

Powder coating is well known for its durability, attractiveness, and unmatched corrosion and environmental protection.  What it is less known for, but perhaps its greatest asset, is its eco-friendliness. Powder coating in Houston boasts many environmental impact advantages when compared with other types of coating processes.

No Volatile Organic Compounds

Volatile organic compounds (VOC for short) are chemicals found in the air from a variety of industries. These can include but are not limited to liquid paint and paint strippers, adhesives, cleaners, pesticides, air fresheners, and gasoline fumes. Powder coating and liquid paint coating industries are closely related but vastly different when it comes to environmental impact. All coatings need time to cure to reach maximum durability. Liquid coatings release VOCs as they cure and also as they are applied. While some liquid paints are classified as low-VOC, they still emit hazardous fumes as they are applied and as they cure over time. Choosing powder coating over liquid coating means not only will you get a more durable, attractive finish, but you can rest easy knowing your order won’t contribute to air pollution. 

Architectural powder coating in Houston covers surfaces from railings, metal facades, window and door frames, vents, soffit and fascia, fences, and more. In a climate like Houston’s, having the ultimate protection against the environment with powder coating saves money on costly renovations due to corrosion or peeling paint. High-rises are relatively new to powder coating, with one of the first high rises to use powder coating being built in New York City in 2020. The 51-story Hudson Yards structure took over twenty thousand pounds of PPG’s Coraflon powder coating to the metal elements for the exterior of the building. The company responsible for the massive undertaking used FEVE, or fluoroethylene vinyl ether, which unlike other architectural powder coatings can be applied at ambient temperature rather than requiring high temperatures to cure. FEVE provides excellent color retention, which for a high-rise is important, as well as high-degradation resistance to air pollution and environmental effects. 

Architects and contractors have been using powder coating shops in Houston for decades for their structure needs because the protection and durability is unmatched when compared to liquid coatings. Stair and balcony rails, decorative metal facades, vents, etc. all can be powder coated for optimum protection of surfaces. Powder coating surfaces for large buildings and commercial buildings is optimal, as the longevity and durability of the coatings makes it a cost-effective option. For high-rises specifically, keeping the exterior looking new for as long as possible is desirable because of the impracticality of frequent touch-ups and repairs.

Powder coating in Houston is more than just spraying the coating, curing, and handing off to the client. Proper preparation methods as well as making sure powders are not contaminated ensure that the client gets the most life out of the coating and that the coating looks flawless if it is on a visible surface. 

When it comes to corrosion resistance, industrial powder coatings in Houston are known for their high level of durability. Corrosive environments are more than industrial zones that handle chemicals both liquid and airborne, with the outdoors being the main corrosive environment powder coated machinery and products are exposed to. In Houston, the outdoors subjects machinery, buildings, vehicles, park equipment, etc. to high heat, high humidity, and in some areas higher levels of general pollution because of its vast number of industrial plants. 

Also, because of Houston’s relative proximity to the coast of the Gulf of Mexico, there is a higher level of sea salt in the air that also can be highly corrosive to metals not protected by powder coatings. To determine if a coating gives maximum durability to the object it is protecting in an area, real-world testing in the location of the powder coating shop/client’s area is a good idea. While this isn’t practical for everything, many powder coating manufacturers should be able to inform powder coating shops in Houston what the best coating systems are for different needs.

The biggest difference between thermoset powder coatings and thermoplastic powder coatings is how they react under high temperatures. Thermoplastic coatings will melt and turn liquid again under high heat because they do not chemically react with the surface they adhere to. Thermoset coatings will not melt under high temperatures and are therefore used in industries where the powder coated object will be subjected to harsh conditions. The science behind thermoset powder coatings in Houston is a chemical process called cross-linking during the heat curing process. After it has cooled and set, the thermoset powder maintains its hardness when heat is reintroduced. 

Polyester Thermoset Powder

This type of thermoset powder is the most commonly used powder coating in Houston. Over 60 percent of the market uses polyester-based powder coatings because of its durability and ability to withstand constant outdoor exposure.

Powder coating is a great option to coat metals like aluminum and protect them from a harsh environment. The powder coating method ensures a durable, long-lasting finish that is environmentally friendly and cost-effective. However, to get the durability you expect out of powder coated aluminum, pre-treatments are necessary to make an optimum surface for the powder coating to stick to.

The first step in pre-treatment of aluminum for powder coating is degreasing. The method of degreasing for the aluminum will depend entirely on the surface of the metal and the pollutants involved. The three primary methods of degreasing aluminum for powder coating are solvent cleaning, vapor cleaning, and emulsion cleaning. Solvent cleaning is the best method if you need to preserve the surface of the metal. Heavy grease and oil are removed from the surface using a solvent-soaked cloth and wiping the surface clean. Emulsion cleaning and alkali cleaning use a solvent with a higher pH and a dipping method. The metal is dipped in the solvent for a few minutes, removed, and rinsed.

Removing rust is the second pre-treatment step for powder coating aluminum in Houston. Corrosion is a major weakness for metal, and the whole reason behind powder coating is to prevent corrosion. However, that doesn’t mean a surface is ruined if rust is present. It can be removed and then powder coated to further protect the metal from further corrosion. Rust is easily dissolved with acid, so this pre-treatment step is relatively simple. This method will also require a rinse afterward.

Professional painters and industrial powder coaters in Houston will tell you that a job is only as good as the prep work.  Poor prep work?  Poor job. While often referred to as sandblasting, that is a misnomer as many types of media are available to be used and sand is not typically one of them.  The specifics of the job, and the type of stripping you need to do, will determine what kind of media you use. 

Aluminum oxide is the most frequently used media form for prep work before industrial powder coatings. Its hardness and strength make it the perfect media to prepare surfaces for powder coating where the removal of rust or previous coatings is necessary.  Aluminum oxide works best with harder metals like titanium and stainless steel but can work with softer metals if enough care and attention is given. It is great at removing old powder coating as well. It can be reused, and as it is expensive, using it in a media blasting cabinet where it can be recovered is typical practice.

Industrial powder coating works best with a well-prepped surface. Foreign contaminants such as dirt, oils, old paint, etc. can create an imperfect finish.  Imperfect finishes are not as durable and do not look as nice. While not completely necessary and technically optional, media blasting before coating is considered an essential step by many professional industrial powder coating shops in Houston. 

Powder coating in Houston is a vast industry with a plethora of uses. Outdoor furniture, architectural use, industrial use, municipal and infrastructure possibilities, etc. all benefit from powder coating in one way or another. Powder coating is a dry powder made from a mix of curatives, flow modifiers, and leveling agents. The powder is applied with a sprayer to electrostatically charged surfaces and then cured in an oven. Thermoplastic powder coatings fuse to the surface using heat and can melt after the curing process if reintroduced to excess heat. Thermoset powder coatings become set in their physical and chemical properties after their initial curing process, making them more durable and appropriate for use in industrial settings where exposure to high heat and chemicals is likely. 

When you make an appointment with Houston Powder Coaters to discuss your powder coating needs, you will quickly find out that because of HPC’s size and high output, they have a great relationship with many powder coating suppliers. They can quickly get you what you need if they do not have it in stock. They also work with powder coating suppliers to provide custom, specialty colors to clients who require specific colors for their products due to HOA restrictions, safety restrictions, or simple logo matching, etc. HPC’s special order colors are any color that exists on the RAL color chart for powder coatings and are considered non-inventory. These are not custom colors, but rather colors not frequently used, so they are not kept in stock. Custom colors can be formulated to match exact shades and specifications when provided with a swatch.  Whether you want to match your new powder coating to an existing coating or match it to your company logo, Houston Powder Coaters can get it done.

Fusion bonded epoxy in Houston is a type of powder coating that is classified as a protective coating. It is applied by applying the coating to an already cleaned and preheated to over 400 degrees Fahrenheit surface. As the epoxy powder is applied, it melts and fuses to the surface, creating a protective barrier. Because fusion bonded epoxy (FBE for short) is a thermoset coating, it cannot go back to its original form and further heating of the FBE coated surface will not allow the FBE to melt. This is great for industries where FBE is needed to protect the surface from corrosive materials and elements such as water, chemicals, heat, UV rays, and more.  FBE is different from other powder coatings in that it is used mainly in industries such as the oil and gas industry and the space industry.  In oil and gas, FBE in Houston is used to coat the interior and exterior of pipelines to ensure maximum protection from the corrosive materials the pipeline is exposed to. 

While traditional powder coating can be used for a myriad of things, FBE is best suited to heavy industry, as it is not necessary or suitable for everything.  Depending on the usage of what you need powder coated, traditional powder coating methods can do their job efficiently.  Unlike FBE, traditional powder coating relies on spraying the powder onto an electrostatically-charged surface, then baking the powder onto the surface in large batch ovens.  Metal patio furniture, public space items such as park benches, bike racks, etc, as well as the appliance industry all benefit from traditional powder coating in Houston.

Architecture/Building Powder Coating

The architecture and building industries use powder coating in many different ways. When it comes commercial buildings, whether they be skyscrapers, smaller buildings, or large warehouses, many aspects of the structure can benefit from powder coating in Houston. Door and window facades benefit from powder coating because of their constant exposure to the elements. Other architectural elements that can be powder coated are metal facades, stair railings, metal fencing, soffit and fascia, light poles, and more. 

Oil & Gas Industry Powder Coating

The oil and gas industry uses powder coating in Houston for all kinds of things. Most notable is powder coating the interior and exterior of pipes for pipelines to protect the integrity of the materials. Oil and gas pipelines can carry corrosive chemicals, so they require great protection against corrosive and abrasive elements, and fusion bonded epoxy coatings in Houston do just that. The powder coating industry in Houston also works with oil and gas companies to protect certain elements of their refineries, storage tanks, and field equipment.

Powder coating has taken over global industries because of its versatility, environmental friendliness, durability, and more. Not a day goes by where you do not see at least one item that has a powder-coated element. That bright red tool chest in your garage? Powder coated. The transformers on your neighborhood power lines? Powder coated. Exercise equipment, mailboxes, sports equipment, park play areas? Powder coated. They all benefit from the durability of powder coating in Houston.

There are many industries across the world that benefit from powder coating.  The architecture/building industry, oil and gas industry, appliance and automotive industries, etc., all make use of powder coating for their products and services in one way or another. 

Appliance Powder Coating

Appliances benefit from powder coating because many household appliances deal with moisture or potentially corrosive chemicals on a daily basis.  Refrigerators can be powder coated on the front panels and side panels, which is great because they can become grimy from dirty fingers and need regular cleaning to remain shiny and new.  Without proper coatings, regular cleaning and usage of a refrigerator can have it looking old and worn before its time.  Dishwasher racks are also frequently powder coated to withstand the corrosive detergents and high temperature water required to clean and sanitize dishes.  Water heaters, washer and dryer exteriors, and air conditioner cabinets are also frequently powder coated to protect them and ensure long usage.

Automotive Industry Powder Coating

There are many aspects of the automotive industry that benefit from powder coating.  There is even a new clear top powder coat for the exterior of vehicles, and door handles, bumpers, wheel rims, etc. have been utilizing powder coating in Houston for a long time. Vehicles are subject to the environment on a daily basis, as well as gasoline, oil, and other chemicals regularly. They are also not inexpensive and need to last for years if not a decade or more without falling apart and rusting, and powder coating provides great protection.

In broad terms, there are two types of powder coating in Houston that industries use today.  These are thermoplastics and thermosets. Thermoplastic powder coating is physically bonded to the surface with the introduction of heat.  This requires batch baking that sets the powder coating by turning into liquid form.  Thermoplastic coatings are thicker and tend to be more durable than thermoset powders. Thermoplastic powders are used in a variety of industries, from the automotive industry to the appliance industry and more.  Thermoset powders are chemically bonded to the surface after they are fully cured, which makes them appropriate for use in industries where conditions are harsher, especially temperature because heat will not affect the coating.

Polyvinyl Chloride (PVC)

Polyvinyl chloride powder coating in Houston (PVC for short) is one type of thermoplastic powder. PVC requires a temperature of 400 degrees Fahrenheit to set, so if the underlying substrate is unable to withstand that high temperature, PVC will not be an appropriate coating.  Polyvinyl chloride is FDA approved for use in the food industry.  It is also acceptable to coat chain-link fencing amongst other things.

Powder coating has been around for several decades—specifically since the 1940s. For most of its history, the technology and materials used in the process are widely utilized in industrial applications that require specialized protective coatings. However, multiple fusion-bonded systems are now available to the average consumer who find simple kits for surprisingly cheap prices.  Since powder coatings are more effective at protecting surfaces than simple paint, using it for the purposes of outdoor furniture refinishing (or other hobbyist projects) can be very attractive to the DIY-minded.  However, there are several reasons why professional powder coating services are worth a little extra investment.

Whether you’re looking to powder coat something yourself or send it to a small shop that promises big results, be aware that there are many factors that can and will affect the final quality of the finish. Commercial/industrial powder coaters operate under strict regulations, work with high-end and expensive commercial equipment, and bring decades of experience with them.  A DIY home powder coating kit might claim to offer safe application, but it’s naive to overlook the many protections that professional powder coaters put into place.  Proper ventilation, respiration, and handling/disposal of the powder & media all require careful consideration.

Also, professional coaters follow surface preparation and quality control standards that far exceed the capabilities of amateurs.  The removal of rust, grease, and other contaminants ensure a clean surface for which the powder will adhere to.  Furthermore, deep anchor patterns created by these processes allow for the powder to sink further into the metal to better protect against dings, chips, and abrasions.  As you can guess, these services cannot be offered by anyone other than a professional powder coating facility.

In the pursuit of bringing hydrocarbons to market, there are many obstacles, both natural and man-made. Some of these difficulties can be circumvented, but others, like corrosion, are unavoidable. As much as oil and gas production companies would love to dodge this process altogether, it’s a natural part of chemistry and physics, and it’s not going anywhere any time soon. Over the decades, many technologies have been created to resist or prevent corrosion-damage to pipelines. These pipelines are essential to the delivery of hydrocarbons, but are susceptible to corrosion damage from the heat, moisture, and abrasives that are often present in these working conditions. One such technology used in the battle against corrosion is fusion bonded epoxy coatings (FBE).

FBE coatings are supplied by multiple manufacturers.  Axalta is a leading provider of protective coatings throughout North America, offering an array of high-tech FBE options. Axalta Nap-Gard® 7-2500 Fusion Bonded Epoxy is one such coating, designed to provide corrosion protection in the demanding oil and gas production environment. In addition, Nap-Gard® 7-2500 is used in transporting wastewater and saltwater, each of which present their own challenges that must be addressed.

Nap-Gard® 7-2500 is designed to provide protection for both internal and external surfaces of pipeline. The protection of both surfaces is important: internal surfaces are exposed to chemically-active hydrocarbons, while outside surfaces can be exposed to high heat, high pressures, and abrasives such as salt.  The 7-2500 specification is formulated to withstand high temperatures of 107°C (225°F)—vital heat protection in the unforgiving oil and gas production environment. In addition to providing this protection for oil and gas applications, the product complies with NSF-61 specification, meaning that it’s approved for transporting potable water.

With the increase of environmental regulations making solvent-based corrosion protection expensive and complicated to apply and dispose of, protective powder coatings such as zinc-rich primers offer premium corrosion protection without harming the environment.   Zinc-rich primers are considered sacrificial coatings, a subset of protective powder coatings meant to dramatically slow down the process of corrosion if the top layer is damaged.    This makes them the perfect coating for steel in highly corrosive environments.  Zinc-rich primers are great for use in marine, tanker, or underground environments, all of which are considered immersive environments.

There are two types of zinc-rich primers: inorganic and organic.  Organic zinc-rich primers are primers that use binders such as epoxy, polyurethane, or alkyd, etc.  More commonly used for highly corrosive environments on oil rig platforms, chemical plants, and more, organic zinc-rich primers require a top-coat to be long-lasting.   

Inorganic zinc-rich primers do not require top-coats in more mild atmospheric environments and provide better galvanic protection overall.  Inorganic zinc-rich primers usually use only silicate as a binder and is applied as a powder using the blast method on “white” metal, metals that are light-colored alloys.  This is the type of zinc-rich primer Houston Powder Coaters uses.

Polyester powder coating technology has been around since the 1970s and accounts for 30-45 percent of powder coating product sales globally.  There are two main categories of polyester powder coatings used in the industry today: TGIC (an acronym for the chemical compound curing agent it uses, triglycidyl isocyanurate), and HAA.  HAA polyester powder coating uses β-hydroxyalkyl amides as its curing agent and is often called TGIC-free or Primid polyester powder coating after the brand of curative used in most HAA powder coatings.  While both categories of polyester powder coatings perform relatively similarly, there are some pros and cons that can tilt a company toward one or the other. 

TGIC coatings typically offer better chemical resistance and corrosion resistance than their TGIC-free counterpart.  The HAA curing mechanism can release water, which makes the coating slightly more water soluble than TGIC-polyester.   Because of its slight water-solubility, HAA coatings are more susceptible to acidic and alkaline chemicals.  All of this makes HAA-polyester less corrosion resistant than TGIC-polyester.  However, with different formulations, a Primid polyester coating can perform on par with TGIC. When it comes to impact and abrasion resistance, flexibility, and hardness, TGIC and TGIC-free polyester powder coatings are the same. 

For application and curing, TGIC-polyester cures at a lower temperature than HAA-polyester (roughly 290 degrees Fahrenheit and 330 degrees Fahrenheit respectively).  Many companies find HAA-polyester applies more easily and sticks to nooks and crannies better than TGIC-polyester.  Thickness of application varies greatly between the two, with TGIC-polyester coating able to reach about 10 mils (250 microns) thickness and HAA-polyester coating reaching 3.5 – 4.0 mils (90-100 microns) thickness.  When it comes to color stability, TGIC-polyester comes out ahead.  HAA-polyester can yellow in color in overbake conditions, while TGIC-polyester has very little color drift over a wide range of cure times and temperatures. 

Unlocking The Benefits Of Powder Coating Finishes

Imagine a world where your car’s paint job lasts longer, your patio furniture doesn’t chip, and your appliances maintain their sleek appearance for years. That’s the world of powder coating - a game-changing technology that has revolutionized the coating industry. In this blog post, we’ll dive into the fascinating world of powder coating, exploring its components, processes, and advantages over conventional liquid coatings. Get ready to unlock the benefits of this durable, cost-effective, and eco-friendly finishing solution.

Key Takeaways

Powder coating technology is a dry finishing technique that offers uniform finishes, enhanced durability and diverse colors.

It utilizes an electrostatic process for even coverage and has two primary materials: thermoset & thermoplastic.