NACE Paper No.

MECCOCT18-12533

Influence of Film Thickness and Porosity on the performance of the FBE Coating

Adel S. Botros
AL-QAHTANI PIPE COATING INDUSTRIES
P.O. BOX 1980 31441 Dammam, KSA

ABSTRACT

To improve the integrity of the application process, the coating personnel must have an understanding of
the most common causes of success and failures of the coating. During the coating application, several
factors influences on the coating. This paper will discusses how the film thickness and porosity will effect
on the performance of the FBE Coating.

Keywords: Film Thickness, Porosity, FBE performance

INTRODUCTION

Fusion Bonded Epoxy (FBE) was developed in the 1960s by 3M company for small diameter pipes.
Several other manufacturers came up with new formulations to improve the flexibility and all other
properties. Now with the new chemistry and new epoxy resins material available, they are able to succeed
in improving the properties such as Cathodic Disbonding, Flexibility and Abrasion Resistance.
This paper will address the application problems that can affect the performance of the applied coating.

MAJOR FACTORS OF FBE COATING PERFORMANCE

Surface Profile

The surface profile also plays an important factor on the resulting Film Thickness.
Anchor Pattern profile varies on each joint from one end to another, depending on which kind of gauge
is used. The film thickness measurements do not count the amount of powder that fills the valley in the
profile.
 Table 1
Surface roughness profile on actual pipe using 2 methods

PIPE NO. 218992

Digital Profile Gauge Testex Press-O-Film
Readings
µm mils µm mils
End A 78.81 3.2 92.5 3.7
Mid 83.99 3.4 90 3.6
End B 87.34 3.5 95 3.8

(a) (b)
Figure 1: Surface roughness measurement methods- (a) Digital Profile Gauge, (b) Testex Press-
O-Film

Film Thickness

Numerous Specifications with varying range of Film thickness (Low or High DFT range) according to the
service condition of the line pipe project. The FBE Coating (single layer, dual layer or 3 layers) is the
main corrosion protection of the steel piping.
Applying the powder coating on a hot surface can yield a varying DFT according to the temperature it
was applied. The hotter the surface, the thicker the coating, better flow and high porosity.
The production line speed can change from one joint to another causing varying DFT of the applied
coating from one end to another on the same joint.
Slowing production line speed for whatever reason must be accompanied with more guns with lower
powder output. The different types of film thickness gauge equipment gives also different readings.
 25
24
23

Dry Film Thickness (mils)

22
21
20
19
18
17
Reading 1 Reading 2 Reading 3
Start of the Joint 21.1 23.4 21.6
Middle of the Joint 21.8 22.1 22.5
End of the Joint 22 19 23.1

Figure 2: DFT Measurements using Digital DFT Gauge

25
24
23
22
Dry Film Thickness (mils)

21
20
19
18
17
16
15
14
Reading 1 Reading 2 Reading 3
Start of the Joint 20 19 19
Middle of the Joint 22 19 19
End of the Joint 21 17 20

Figure 3: DFT Measurements using Magnetic (Banana) Gauge

Specific Gravity

Specific gravity of the powder can be different than specific gravity of the coating.
Specific gravity of the coating is affected by porosity. Some manufacturer’s report in their Technical Data
Sheet, the specific gravity of the powder and others, the specific gravity of the coating or both. So when
calculating the coverage you should know based on the specific gravity of the powder or the applied
coating.
Specific gravity of powder versus cured film:

Powder:
The density of the powder was carried using an air pycnometer (Model no. ACCUPYC, Manufacturer:
Micrometrics) in accordance with CAN/CSA Z245.20 paragraph 12.6 Procedure B.

Cured film:
The density of the film was carried using a density tester (Model no. XS 603S, manufacturer : Mettler).
Input the room temperature. Set zero. Measured the weight of the film. Placed film to the basket within
pure water. The density was calculated from the tester.
 Cure condition : 230℃, 5mins
 Film thickness : 600~700 ㎛ (24 to 28 mils)

Table 2
Test Result of Specific Gravity of Powder and Cured Film
Specific Gravity No.1 No.2 No.3 Average

Powder 1.402 1.415 1.420 1.41

Film 1.351 1.380 1.372 1.37

Porosity
Foams and voids can be found when applying any FBE Coating. Several reasons can cause high level
of porosity and listed as Follows:
 Moisture Content of the Powder
 Application Temperature
 Gun Position
 Contamination
 Excessive use of Recycled Powder
 Dew Point of the compressed air in Fluidizing Bed and Powder Guns

Moisture content of the powder:

Higher moisture content of the FBE powder during production or the formulation generates gas during
the reaction; can affect the flow of the powder and causes voids during application.

Application temperature:
The high application temperature gives good adhesion performance and also increases the rating level
of the foam.

Gun position:
The way the guns have been set up has a lot to do with creating foam. Spreading the spray gun and
applying a thin layer of powder before building the required DFT helps lower the percentage of foam in
the coating. Higher number of spray guns delivers smaller amount of powder per gun also helps decrease
the level of porosity.
Contamination:
The porosity on the interface & cross section can be affected by the surface contamination. Oil under the
slivers also contains contamination, with heat, the slivers will open up and the contamination will volatized
and cause void on the applied FBE.

Recycle Powder:
The reclaim powder most of the time contain a higher percentage of moisture absorbed during transport
from the coating booth to the dust collector and returned back in the fluidizing bed.

Dew Point:
The Dew Point of the compressed air supply in the Fluidized Bed should be checked more often. The air
should be dry so it cannot introduce moisture to the powder.
Powder box:
The powder box should not be opened immediately after it was transferred from the cold storage room
to the production cold room. The powder boxes should be kept to room temperature to avoid the
condensation that can introduce moisture to the powder.

BAD POROSITY GOOD POROSITY

Cross Section Cross Section

Interface Contamination Interface Contamination

Figure 4: Comparison between a good and bad porosity

 CONCLUSIONS

 Digital profile gauge gives an accurate reading and you can print the graph for your record.

 Figures 2 & 3 shows the Dry Film Thickness at the same spot using two different gauge and
showing two different readings. Dissimilar film thickness will affect the performance of the coating
when tested for Cathodic Disbondment and Hot Water Adhesion.

 Calculated the film thickness should be using the density of the powder not the cured film to
achieve the right film thickness with the right amount of powder.

 Moisture content of the powder, application temperature, gun position, contamination, excessive
use of recycled powder, dew point of the compressed air in fluidizing bed and powder guns
creates porosity during application can reduce the adhesion of the FBE to the steel surface.

REFERENCES

1. A. Kehr, Fusion Bonded Epoxy: A Foundation for Pipeline Corrosion Protection, 2003
2. Dennis Neal, Fusion Bonded Epoxy Coating Application and Performance.1998
3. Dennis Neal, Variables in Measuring Coating Thickness and Proposed New Method, June 1995
4. George Mills, Sources of Bubbles, Foam and Voids in Coating, 2000
5. NACE RP 0394: Standard Recommended Practice – Application Performance and Quality Control
of Plant Applied Fusion Bonded Epoxy External Pipe Coating (Houston, TX, NACE), 2013