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Anti-corrosion Painting Process for Power TowersHigh-end solution

Power transmission towers for severe industrial / marine / tropical environments. The XGE-HY iron red high-strength epoxy primer + XGE-930 silver white fluorocarbon topcoat form a high-performance two-coat system, presenting a simulated new galvanized metal finish. It resists UV, salt spray, and industrial atmospheres for 8-10 years.

SubstrateHot-dip galvanized steel

Systemdouble coating system

primerXGE-HY Iron Red

topcoatXGE-930 Silver White

Protection Life8-10 years

corrosion environmentC4-C5 / Industrial / Marine / Tropical

System Overview · Coating Structure

Cathead-shaped transmission tower · Silver-white fluorocarbon topcoat with new-like galvanized metal finish

XGE-930 Silver White TopcoatFEVE Fluorocarbon · Ultra-high Weather Resistance · Zinc-like Metal Look

XGE-HY Iron Red PrimerHigh-strength epoxy · Industrial-grade adhesion

Hot-dip galvanized substrateISO 1461 Galvanized layer

Total dry film thicknessPrimer 120μm + Topcoat 100μm ≥ 220μm

XGE-HY Primer

Primer · High-strength epoxy · Industrial-grade adhesion · Iron red

zinc-rich epoxy100-150μm dry film

XGE-930 Topcoat (Silver White)

Topcoat · Fluorocarbon/Ultra-high weather resistance · Zinc-plated appearance

FEVE Fluorocarbon80-120μm dry filmMetal texture adjustable.

Construction phase process

Large components of power towers + complex nodes, 5-stage closed-loop quality control

Phase One · Preparation

Substrate inspection

Comprehensive inspection of galvanized layer, welds, joint plates, bolts and tower base; sharp edges rounded to R≥2mm.

Standards: ISO 1461 · Sharp Edges R≥2mm

Phase Two · Surface Treatment

Sandblasting cleaning

Oil-free abrasive sanding to near-white grade Sa3.0, Rz 60-100μm, visible metallic luster.

Standards: ISO 8501-1 Sa3.0 · Rz 60-100μm

Phase Three · Primer

Spraying XGE-HY

Iron Red Epoxy Primer, Airless Spraying 2 coats, Atomization Pressure 18-22 MPa.

DFT: 100-150μm · Intercoat Interval: ≥12h / 25℃

Phase Four · Topcoat

Spraying XGE-930

Silver White Fluorocarbon Topcoat, Airless Spraying 2 coats, Simulating Hot-dip Galvanized Metal Texture.

DFT: 80-120μm · Forced curing: 14d / 25℃

Detailed Construction Process

Critical steps + quality inspection points, rework automatically if unqualified

Substrate inspection: Galvanized layer + Weld seams + Nodes + Tower base

⚑ Quality GateIs the Galvanized Layer Intact?

↺ Realing / Edge repair

Surface treatment: Sanding ISO Sa3.0 · Rz 60-100μm

Surface cleaning: Oil-free compressed air + solvent wiping

⚑ Quality GateIs cleanliness/roughness meeting standards?

↺ Repaint with sanding

Sprayed Primer XGE-HY Iron Red · 100-150μm · 2 coats

Primer drying at 25℃ × 12h · Ventilation required

⚑ Quality GateIs the primer film thickness + adhesion OK?

↺ Repainting base coat

Sprayed Topcoat XGE-930 Silver White · 80-120μm · 2 coats

Topcoat drying at 25℃ for 24h · forced curing for 14d

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

↺ Local patching

On-site Repair - Nodes/Bolts/Welds/Tower Foundations

Comprehensive re-inspection: salt spray / aging / adhesion retesting

⚑ Quality GateOK for accelerated aging testing?

↺ Re-inspection after repair

Delivery · 8-10 years protection · Industrial / Marine / Tropical

Quality Control and Key Parameters

High-end quality control, with 4 new high-end tests added, totaling 11 inspections

Thickness of Galvanized Layer	≥ 85 μm
Blending of Sharp Edges	R ≥ 2 mm
Sandblasting cleanliness/roughness	Sa 3.0 · Rz 60-100μm
Environmental Temperature/Humidity	10-32℃ / RH ≤ 80%
Dry film thickness of primer	100-150 μm
Thickness of the dried topcoat	80-120 μm
Adhesion (Grid Test)	ASTM 0 Grade
Glossiness (60°)	≥ 80 GU
appearance / color	Silver White · ΔE ≤ 1.0
QUV Accelerated Aging Test	2000h · Light retention rate ≥ 70%
Neutral salt spray	1500h · No blistering/No rusting

Key construction points

Sandblasting grade Sa3.0:Near-white metallic luster provides the best adhesion base for fluorocarbon topcoats.
The environmental humidity for fluorocarbon topcoat application should be ≤ 80%, and the substrate temperature should be 3℃ above the dew point.
Silver White Metal Texture Adjusted by Aluminum Powder Addition, Sample Confirmation Before Large-Scale Construction.
Special attention should be paid to re-coating at node boards and bolt connections, with the film thickness not being less than 220μm as a requirement.
High-strength epoxy primer must be used within the applicable period (activation period); construction is prohibited after the applicable period.

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