With the continuous advancement of heavy-duty anti-corrosion coating technologies and the integration of modern spraying equipment—such as high-pressure airless spray systems, solvent-free dual-port sprayers, and powder coating devices—these coatings have evolved to meet more specialized corrosion protection needs. This article, published by the Technical Support Division of Xianghua Coating Phosphate (Chengdu), provides an in-depth overview of the key industries where heavy-duty coatings are applied today.
1. Main Application Areas
Heavy-duty anti-corrosion coatings are primarily used in environments with severe corrosion challenges and industrial sectors that require long-term durability without frequent maintenance. These include:
1. Emerging marine engineering: offshore platforms, coastal structures, and oil rigs;
2. Modern transportation: highway barriers, bridges, ships, containers, trains, railways, cars, and airport infrastructure;
3. Energy sector: hydraulic systems, water tanks, gas storage, petroleum refining equipment, oil pipelines, power transmission facilities, nuclear power plants, and coal mines;
4. Large-scale industrial enterprises: papermaking machines, medical equipment, food and chemical processing tools, metal structures, chemical and petrochemical plant piping, storage tanks, mining equipment, cement plant components, and structures exposed to corrosive media;
5. Municipal infrastructure: gas pipelines, natural gas systems, drinking water facilities, and waste treatment equipment.
2. Development of Modern Industry
The rapid growth of modern industry has created vast opportunities for heavy-duty coatings, extending their use from land-based structures like highways, urban rail transit, and nuclear power plants to offshore and space projects. From traditional sectors to emerging fields, these coatings have found a wide range of applications. For example, seawater desalination projects have opened new markets for heavy-duty coatings, especially in arid regions like the Middle East, where water scarcity is a major challenge. Seawater desalination and utilization projects in countries such as the U.S., Japan, and Israel face constant exposure to seawater, which demands highly resistant coatings. As a result, water-based heavy-duty anti-corrosion coatings have emerged and are gaining popularity. In industrial coatings, heavy-duty anti-corrosion coatings now account for 5–7% of total usage, showing significant growth over the years.
3. Environmental Protection Promotion
As industrial activity increases, so does the emission of carbon dioxide and hydrocarbons into the atmosphere, leading to global warming and various forms of pollution. Some organic compounds react with nitrogen oxides to form harmful ozone, causing secondary pollution. According to statistics, about 20 million tons of hydrocarbons are released annually, with a large portion coming from paint. Paint manufacturing alone emits 2% of solvents, while up to 80% of solvents evaporate during application. To reduce atmospheric pollution, heavy-duty coatings are moving towards high-solids, solvent-free, and water-based formulations. Among these, high-solids and water-based coatings are becoming the mainstream. For instance, the chlorinated rubber coating used on the Sydney Harbour Bridge contained 500g/L of solvents, causing serious environmental issues.
4. Superior Performance and Wider Adoption
High-performance heavy-duty coatings offer multiple advantages:
1. Excellent Corrosion Resistance: Strong adhesion, long service life, and resistance to acid, salt, and seawater. Xianghua Coatings has developed a hybrid coating combining epoxy and chlorosulfonated polyethylene rubber, offering superior anti-aging properties and corrosion resistance.
2. Easy Construction: Can be applied at room temperature and is user-friendly, even for unskilled workers. The construction process is similar to standard two-component epoxy coatings, making it accessible to general contractors.
3. Eco-Friendly: High-solids coatings can achieve up to 90–100% solid content, significantly reducing solvent emissions. Xianghua’s heavy-duty coatings have a solid content of over 75%, some reaching 90%, lowering both environmental impact and cost of use.
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