Resin Epoxy

Green Epoxy Coatings

One of the most environmentally-friendly methods of protective coating is epoxy coating, which is a product of natural and organic resin. Resin, which often comes from coniferous trees and plants, is valued for its ability to synthesize chemically and turn into useful products like varnish, adhesives, perfumes, and epoxy coating, among others.

Epoxy resin is manufactured through a process of polymerization. The organic epoxy resin is combined with catalyzing agents, fillers, and pigments to turn into a dry powder which, when heated, melts and causes a reaction that allows the formation of complex cross-linked polymers. Once cured and dried, epoxy coating provides strong, UV-resistant, and permanent protection to steel materials.

Fusion-Bonded Epoxy (FBE) Coating

Fusion-bonded epoxy coating is a method of applying corrosion-protective epoxy coating to steel pipes, rebars (reinforcement bars), pipes and valves. Epoxy powder is melted at temperature ranges of between 180 to 250°C (360 to 480 °F), and transforms into a liquid element that flows and adheres into the steel surface. Once the liquid powder dries, it cross-links or “fusion-bonds” to the surface of the steel material permanently, protecting the steel structure effectively and permanently.

Fusion-bonded epoxy coatings are used extensively in industries requiring steel pipes and fittings that are corrosion-free. Because epoxy coating is made from environmentally-friendly materials, structures with epoxy coatings do not contain environmentally-hazardous solvents or substances that will come off and cause health and safety risks.

The Epoxy Coating Process

Epoxy coating plants commonly coat bars that are pre-cut in straight lengths of around 40 to 60 feet. The bars are then cut and bent to meet project specifications. The bars are carried through a conveyor system and subjected to the epoxy coating process.

To prepare steel surfaces for the epoxy coating process, blast cleaning is done to remove rust, scales and other contaminants from the steel surface. The end result of blast cleaning is a rough surface finish called a profile. The profile increases the effective surface area of the steel and provides better anchorage for epoxy coating when it is later applied to the steel bar.

Blast cleaning involves the release of compressed air on to the steel surface, propelling abrasives like steel grit, garnet, or coal slag to hit the surface, resulting to pock marks that cleanses and roughens the surface.

After the rebars have been blast-cleaned, they are heated and sprayed with dry epoxy powder. When dry epoxy powder is ejected from spray nozzles they are imparted with electrical charges that are automatically attracted to the already grounded heated bars. The dry powder melts and flows into the steel’s heated surface, anchoring to the ribs and deformations in the surface. The heat also induces a chemical reaction that transforms the epoxy powder molecules into complex cross-linked polymers, forever changing the material into its final state.

A 30-second curing process solidifies the epoxy coating, with an air or water quench introduced to reduce the temperature quicker for easy handling.

The process of manufacturing epoxy coating, and the coating process itself, are efficient and environment-safe, with little material lost to the atmosphere, even lesser waste, and zero contaminants. Because of the environmental consideration and to comply with environmental safety standards, epoxy coating remain a viable choice to protective coating.

About the Author

Steve A. Parker, Sr. Estimator, RaiderPainting.com – the preferred painting contractor for building owners and facility managers of commercial and industrial properties nationwide. Call 877-724.3371 for a free Epoxy Coatings Estimate.

DIY Introduction to Using Epoxy Resins

Jack Daniel’s Epoxy Resin Flask $26.99 From the Jack Daniel’s Collection. Jack Daniel’s Vintage Flask. Features an antiqued Jack Daniel’s Charcoal Mellowed poster design on the front of the flask. Holds 6 oz. The twist-off stainless steel captive top is permanently attached to the flask to prevent loss. Made of stainless steel with a satin finish. Officially licensed product.Jack Daniel’s reminds you to drink responsibly….

Alessi Dressed Round Tray in Steel Colored with Epoxy Resin, Black 13.75 $70.00 Round tray in 18/10 stainless steel mirror polished with relief decoration. The table set Dressed was designed by Marcel Wanders. Traditionally, the rules would require that decoration be applied in the most important and most visible areas of the object. Wanders, on the other hand, applies it to secluded areas, a little out of sight, sometimes even in areas that aren’t normally visible at all, so…

Alessi Dressed Round Tray in Steel Colored with Epoxy Resin, White 13.75 $70.00 Round tray in 18/10 stainless steel mirror polished with relief decoration. The table set Dressed was designed by Marcel Wanders. Traditionally, the rules would require that decoration be applied in the most important and most visible areas of the object. Wanders, on the other hand, applies it to secluded areas, a little out of sight, sometimes even in areas that aren’t normally visible at all, so…

Epoxy Shaping 101 with Greg Loehr $24.71 Why Epoxy? Epoxy resin and EPS foam have been around for years now but these materials haven’t been widely used because of a scarcity of information of just how easy it is to make surfboards with this new technology. Epoxy resins and hardeners have vastly improved in the last several years making them much easier to use. Boards made with EPS Foam and Epoxy resin tend to be lighter, stronger, flex …

Stoner 95141 Invisible Glass Windshield Chip Repair Kit $9.11 Now you can easily repair chips, stars, and dings in your windshield and prevent the damage from spreading. The Invisible Glass Windshield Chip Repair Kit saves you the time and expense of windshield replacement. You can do it yourself in just minutes without mixing. Cures in sunlight. This patented repair method evacuates air and fills the cavity with UV cured resin that clears and bonds the loos…

Zeva Nail Guard – Triple Protection Formula – Nail Strengthener, Base and Top Coat Nail Polish – .5 Fl Oz / 15 Ml $15.00 Looking for Zeva’s Titanium Nail Fortifier? This is it! We have changed the name to Zeva Nail Guard. Zeva’s Nail Guard is the best one-step nail strengthener polish that you can buy. Zeva’s Nail Guard gives your nails a beautiful, high-gloss shine while supplying incredible protection for soft or fragile nails. Our special, three-resin formula contains polyester resin for durability, epoxy resin …

FX Rock Hard Epoxy Bonding Resin 2 oz (2 Pack) $4.22 When you want solid hold for your style, bond it with Rock Hard Epoxy Bonding Resin. Indestructable hold for any doo you want. Rock hard hold for your hard rock style….

Loctite 1405604 0.85-Ounce Plastic Syringe Epoxy Marine Gel $2.84 The heavy-duty design of this laser fax is ideal for small-to-medium businesses or home offices with its ability to handle heavy workloads. Features include 12 pages-per-minute printing speed, Caller ID, Quick Scan, a 14.4Kbps modem, a fax transmission speed as fast as 8 seconds per page, 170-page memory that stores incoming faxes even when you’re out of paper, and 20-station broadcasting. Other f…

MG Chemicals Silver Conductive Epoxy, 14g (0.35 oz) : 8331-14G $28.95 M.G. Chemicals Conductive Silver Epoxy, 14g (0.35 oz) Two 7g syringes, 3ml each This two part silver epoxy offers high electrical conductivity and strong conductive bonding. Use in place of traditional soldering on heat sensitive components. Good for…

Arctic Silver Thermal Epoxy $9.71 Arctic Silver Thermal (not retail packaged) Adhesive features: Made with 99.8% pure micronized silver. 62% to 65% silver content by weight. Superior thermal conductivity. Greater than 7.5 W/m°K Temperature range: – 40C to >150C (Bond strength is weakened at very low temperatures due to crystallization.) Negligible electrical conductivity. Arctic Silver Thermal Adhesive was formulated to conduct h…