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Anti-corrosion coating process for communication towers.enhancement plan

Communication towers for coastal areas / high UV radiation regions. The XGE-920 gray primer + XGE-922 acrylic polyurethane topcoat (custom color) form a reinforced two-coat system, featuring excellent weather resistance, UV resistance, and salt spray resistance, extending the protective lifespan to 5-8 years.

SubstrateHot-dip galvanized steel

Systemdouble coating system

primerXGE-920 Gray

topcoatXGE-922 Custom Color

Protection Life5-8 years

corrosion environmentC3-C4 / Coastal / High UV

System Overview · Coating Structure

Steel Tower Structure · Custom Indigo Topcoat · Total film thickness ≥ 180μm

XGE-922 Topcoat (Custom)Acrylic polyurethane · UV-resistant / salt spray resistant · Color customizable

XGE-920 PrimerEpoxy/Modified Epoxy · Excellent adhesion to galvanized surfaces

Hot-dip galvanized substrateISO 1461 Galvanized layer

Total dry film thicknessPrimer 90μm + Topcoat 90μm ≥ 180μm

XGE-920 Primer

Primer · Excellent adhesion to galvanized surfaces · Gray

Epoxy/Modified Epoxy80-100μm dry film

XGE-922 Topcoat (Custom)

Topcoat · Acrylic Polyurethane · UV-resistant / Salt spray resistance

Acrylic Polyurethane70-100μm dry filmColors can be customized

Construction phase process

Substrate inspection to final delivery, 5-stage closed-loop quality control, tailored for coastal/High UV environments

Phase One · Preparation

Substrate inspection

Verify the integrity of the galvanized layer; mark rust, white rust, and damaged areas.

Standards: ISO 1461 · Blending of Sharp Edges R≥2mm

Phase Two · Surface Treatment

Sandblasting cleaning

Oil-free abrasive sanding Sa2.5, roughness Rz 50-85μm.

Standards:ISO 8501-1 Sa2.5 · No oil or aquatic gas

Phase Three · Primer

Spraying XGE-920

2 passes of airless spraying with a wet film thickness of about 150μm, thick paste-based gray primer.

DFT: 80-100μm · Intercoat Interval: ≥8h / 25℃

Phase Four · Topcoat

Spraying XGE-922

2 passes of airless spraying with acrylic polyurethane topcoat, color customizable.

DFT: 70-100μm · Forced curing: 7d / 25℃

Detailed Construction Process

Critical steps + quality inspection points, rework automatically if unqualified

Substrate inspection: galvanized layer + sharp edges rounded R≥2mm

⚑ Quality GateIs the Galvanized Layer Intact?

↺ Realing / Edge repair

Surface treatment: Sanding ISO Sa2.5 · Rz 50-85μm

Surface cleaning: Oil-free compressed air + solvent wiping

⚑ Quality GateIs cleanliness/roughness meeting standards?

↺ Repaint with sanding

Sprayed Primer XGE-920 Gray · 80-100μm · 2 coats

Primer drying at 25℃ × 8h · Ventilation required

⚑ Quality GateIs the primer film thickness + adhesion OK?

↺ Repainting base coat

Sprayed Topcoat XGE-922 Customized · 70-100μm · 2 coats

Topcoat drying at 25°C for 24h · forced curing for 7d

⚑ Quality GateIs the film thickness, gloss, and color difference acceptable?

↺ Local patching

On-site Repainting - Node Plates/Bolts/Welds

⚑ Quality GateFinal Inspection Passed?

↺ Re-inspection after repainting

Delivery · 5-8 years protection · UV resistance / salt spray resistance

Quality Control and Key Parameters

Four additional upgrade tests added to the base solution: roughness, gloss, QUV aging, salt spray

Thickness of Galvanized Layer	≥ 85 μm
Blending of Sharp Edges	R ≥ 2 mm
Sandblasting cleanliness/roughness	Sa 2.5 · Rz 50-85μm
Environmental Temperature/Humidity	10-32℃ / RH ≤ 80%
Dry film thickness of primer	80-100 μm
Thickness of the dried topcoat	70-100 μm
Adhesion (Grid Test)	ASTM 0 Grade
Glossiness (60°)	≥ 85 GU · Glossy
appearance / color	Custom Colors · ΔE ≤ 1.0
QUV Accelerated Aging Test	1000h · Light retention rate ≥ 80%
Neutral salt spray	1000h · No blistering

Key construction points

Blending of Sharp EdgesR≥2mm, to prevent early rusting due to insufficient edge thickness.
After sandblasting in coastal projects, the primer must be completed within 4 hours to prevent rust recurrence.
For topcoats in high UV areas, it is recommended to choose lighter colors to reduce the surface temperature of the coating.
Airless spraying pressure: 15-20 MPa, fan overlap of 50%.
Avoid mechanical damage and contact with heavy objects within 7 days after the topcoat is dry.

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