Epoxy coating is the process of applying a thin layer of an epoxy, which includes a variety of typically thermosetting polymer resins, over another material such as plastic or metal. Referred to as the substrate, metal is the most common material that undergoes coating services.
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Also known as polyepoxides, epoxies are formed as a result of a chemical reaction in which an epoxide resin is combined with a polyamine hardener, and thus epoxies fall into the category of copolymers since they are formed from two separate chemicals. Due to the extensive variety of epoxy materials, there is an equally wide range of applications and industries in which epoxy coatings are utilized including: construction, for use in coating the floors of areas (especially of concrete) such as garages and basements; industrial manufacturing, in order to coat the floors of warehouses and processing plants; automotive, for the coating of the exterior surfaces and parts in order for paint to better adhere; residential, for use in the coating of household appliances such as washers and dryers; and petroleum, in order to coat steel oil and gas transmission pipelines. Some advantages of epoxy coatings include high electrical insulation, high thermal conductivity or insulation and chemical- and heat-resistance.
Epoxy coatings are typically two-part coatings, in much the same way that they are copolymers due to their formation from two distinct chemicals. Initially developed as heavy-duty coatings for use on metallic substrates, epoxy coatings actually use less energy than comparative heat-cured powder coatings. Two-part epoxy coatings typically feature low volatility, ultraviolet (UV) resistance and excellent hardness. A more specialized type of epoxy coating is a fusion bonded epoxy powder coating, or more simply, fusion bonded epoxy coating (FBE). FBE coatings are epoxy-based coatings that are also powder coatings. Powder coating refers to any type of coating service in which a thin layer of material that is applied is both dry and free-flowing. As thermoset coatings, FBE coatings are most commonly utilized in the piping applications such as in pipeline construction, pipe connectors and concrete reinforcing bars. As a type of protective coating, FBE coatings are achieved through the use of chemical cross-linking which is assisted by the addition of heat. Chemical cross-linking refers to the formation of a covalent bond, meaning a bond that is developed through the sharing of one or more electrons between polymer chains.
