Coatings

for pipes

INTECH GmbH is actively engaged in supplying 3-layer coatings for pipes. Three layered coatings, also sometimes referred to as 3LPE/3LPP, consist of Fusion Bonded Epoxy, or FBE, adhesive and polyethylene or polypropylene. Our 3-layer coatings are used in pipes that transport oil & gas, water, and other fluids. 3LPE and 3LPP coatings help to protect pipes from corrosion, provide chemical resistance and significantly increase lifetime of the pipelines. In addition, 3-layer PE or PP coated pipes can withstand various temperatures, ranging from extreme cold to the temperatures of up to 80 degrees. Our products are CSA and ISO approved and are used by a wide range of pipe manufacturers, whose products are utilized by some of the largest oil and gas companies in the world.

EN 301A, Fusion Bonded Epoxy
L-5REN2, Adhesive
EJ-EN8, Polyethylene coating
What we offer
Products:

Fusion Bonded Epoxy (FBE), EN 301A

FBE powder coating helps to increase corrosion resistance of the pipes and is used as the first layer in the 3-layer coating systems. Typical applications of the fusion bonded epoxy typically begin with the cleansing of the surface. The main goal at this stage is to degrease the surface and remove rust and any impurities from the surface of the pipe. After that, the pipes are heated, typically to the temperatures ranging from 180 to 240 degrees. The FBE powder is then sprayed on the pipes, usually using electrostatic application method. The charged powder evenly wraps the surface of the pipes and then turns into a solid coating, either from the residual heat or from heating the pipes again. FBE powder coatings have numerous advantages, including efficient application and limitation of waste, compared to alternative options.

Further information about EN 301A Fusion Bonded Epoxy can be found here.

Adhesive, L-5REN2

L-5REN2 is an adhesive that is usually used as a second layer in the 3-layer PE and PP coatings for pipes. The product can be supplied in powder or granule form, depending on the requirements of the customer. The main goal of the adhesive is to bond together the FBE, used as a ground coating and Polyethylene or Polypropylene, as a topcoat. L-5REN2 can be applied by flat die or crosshead extrusion. Exact extrusion conditions will depend on the type of the equipment used and the size of the pipe. Typical thickness for the adhesive is 0.3 mm or greater. L-5REN2 has an outstanding durability and long-term bonding strength.

Further information about L-5REN2 adhesive can be found here.

Polyethylene Coating, EJ-EN8

Polyethylene is often used as an anti-corrosion material in the two- or three-layer coating systems. EJ-EN8 is applied as a third coat to pipes that are used to transport gas, oil or water. EJ-EN8 can be supplied either in powder or granule form, depending on the requirement of the customer, as well as in black or other colours. The product is compatible with a wide range of products, but it is recommended to use it with EN-301A FBE and L-REN2 adhesive.

Further information about EJ-EN8 polyethylene coating can be found here.

What we offer

Three-layer coatings supplied by Intech GmbH provide excellent corrosion resistance, improve expected lifetime of pipes, and can be adjusted to work in extreme temperatures. Our products comply with the CSA, DIN and ISO standards and are widely used by leading pipe manufacturing companies. All three layers supplied by Intech GmbH are manufactured in developing countries, which allows us to offer a competitive solution to proactively compete with European and North American products, while fully complying with the international standards, which results in our products being used in many countries and approved by leading pipe manufacturers.

Technical information and properties of the 3-layer PE coating:

FBE Parameters	Typical Requirements	Testing method	EN 301A
Volatile-matter content (moisture). Loss in weight, %, maximum	0.5	2 h under 105 °C	0.45
Solidification heat, J/g, minimum	30	ISO 11357-5:1999	Complies
Glass-transition temperature, °C, minimum	100	ISO 11357-2:1999 10 °C/min, Тmg	110
Storage time under 25 °C and 65 % R.H., months, minimum	12		Complies
Adhesive Parameters	Typical Requirements	Testing method	L-5REN2
Melt flow index (190 °C/2.16 kg), g/10 min.	2-8	ISO 1133:1997	2.5
Softening temperature, °C, min.	110	ISO 11359-3:1999 10°C/min, 10 N/см³ or ISO 306:2004(according to Vicat)	115
Yield strength under temperature 23 °C, MPa, minimum	10	ISO 527-2:2012 sample of type 1, 100 mm/min	18
Elongation at break under 23 °C, %, minimum	500	ISO 527-2:2012 sample of type 1, 100 mm/min	800
Brittle temperature, %, maximum	-70	dynamic method	≤-70
Water absorption after 1000 h of water exposure under temperature 80 °C, %, maximum	1	ISO 62:2008	0.1
Oxidation induction time under temperature 200 °C and flowing oxygen of 100 mm/min, min, minimum	20	ISO 11357-6:2002	28
Polyethylene Parameters	Typical Requirements	Testing method	EJ-EN8
Melt flow index, g/10 min	0.2-0.6	ISO 1133:1997 (190 °C, 2.16 kg)	0.5
Softening temperature, °C, minimum	115	ISO 11359-3:1999 10 °C/min, 10 N/сm²	118
Yield strength under temperature (20+3) °C, MPa, minimum	18	ISO 527-2:2012 sample of type 1, 100 mm/min	20
Elongation at break under temperature -45 °C, %, minimum	100	ISO 527-2:2012 sample of type 1, 50 mm/min	300
Stress cracking resistance under temperature 50 °C, h, minimum	5000		＞5000
Brittle temperature, %, max.	-70		≤-70
Electrical volume resistivity, Ω cm, minimum	1014		5*10¹⁵
Penetration under temperature 60 °C, mm, maximum	0.2		0.15
Induction period of oxygen conduction under temperature 200 °C and flowing oxygen of 100 ml/min:		ISO 11357-6:2002
- initial composition, min, minimum;	80		150
- after 500 h of air aging under 120 °C, %, maximum change	50		30
- after 30 days of water exposure under temperature 95-100 °C, %, maximum change	50		32

Main characteristics of the finished three-layer coating (testing on cut template)

Characteristic	Temperature	Typical Requirements	Results of Intech`s 3LPE coating
Impact strength, J/mm of thickness, minimum, under temperature	minus (45±3)°C	7 - 8	≥8
	minus (40±3)°C	6 - 10	≥10
	(25±10)°C	5 - 8	≥8
	(50±5)°C	3	≥6
	(60±3)°C	3 – 6	≥6
Adhesion, N/cm of width, minimum, under temperature	(25±10)°C	70 – 200	300
	(40±3)°C	30	220
	(60±3)°C	50 – 100	160
	(80±5)°C	50 - 75	120
Adhesion decrease, % from initial value, maximum, after 1000 h of water testing under temperature	(20±5)°C	30	20
	(40±3)°C	33	21
	(60±3)°C	33	22
	(80±3)°C	50	30
Area of coating cathodic disbandment, cm², maximum, after 30 days of tests in 3% NaCl solution under temperature	(20±5)°C	3-5	Complies
	(40±3)°C	10
	(60±3)°C	7 - 10
	(80±3)°C	15
Coating transient resistance in 3% NaCl solution under temperature (20±5) °C, Ω m², minimum	-	10¹⁰	5*10¹²
Resistance to temperature cycling, number of cycles without scaling and cracking, minimum, under temperature	from minus (50±3)°C to (20±5)°C	10	≥10
	from minus (60±3)°C to (20±5)°C	10	≥10
Resistance to cutting, residual thickness of coating on the test area, mm, minimum	-	1.5	2.0
Tensile strength at break of scaled coating, MPa, minimum, under temperature	(20±5)°C	12 - 18	23
	(60±3)°C	10 - 15	18
Elongation at break of scaled coating, %, minimum, under temperature	minus (45±3)°C	100	280
	minus (40±3)°C	100	300
	(20±5)°C	200 - 350	700
Indentation resistance, mm, maximum, under test temperature	(20±5)°C	0,15 – 0.2	0.1
	(40±5)°C	0.3	0.12
	(60±3)°C	0,2 – 0.3	0.15
	(80±3)°C	0.4	0.28
Coating adhesion under 23 °C after water exposure for 1000 h, N/cm, minimum	under 60 °C	50	250
	under 80 °C	70 - 100	220
	under 95 °C	100	200
Scaling area of coating under cathodic polarization after air exposure for 30 days, cm², maximum	under 60 °C	10 - 15	Complies
	under 80 °C	20	Complies
Heat aging resistance of coating polyethylene layer. Elongation at break after air exposure for 100 days, %, minimum	under 110 °C	300 - 400	600
	under 120 °C	400	500
Decrease of elongation at break of scaled coating after 1000 h of air tests under (110±3) °C, in % of initial value, maximum		20 - 25	15
Change of melt flow index of polyethylene after air exposure under temperature (110±3) °C for 1000 h, in % of initial value, maximum		20 - 25	16
Elongation decrease after 500 h of exposure in artificial light weathering chamber under radiation intensity of 120 W/m², %, maximum		30	20
Stress cracking resistance under temperature (50±3) °C, h, minimum		1000	≥2000
Degree of cure ∆Tg, °C, within limits		-3≤∆Tg≤+2	Complies
Shrinkage of coating polyethylene layer under temperature 140 °C, %, maximum		45	20

Products:

Adhesive, L-5REN2

L-5REN2 is a polyethylene adhesive for the three-layer coating systems, in granule form. The product is also available in powder form. L-5REN2 is suitable to operate in the temperatures from -45 C up to + 84 C.

The product fulfils the international standards, such as ISO and CSA, when appropriate industrial manufacturing standard procedures are implemented, and a continuous quality system is present. L-5REN is best used in combination with PE topcoat, EJ-EN8 and a compatible FBE, such as EN 301A.

Characteristic	Testing	Requirement	Typical value of L-5REN2
Density, g/cm³	ISO 1183	≥0.920	0.932
Melt Flow Rate (190℃, 2.16Kg), g/10min	ISO 1133	≥1.0	2.01
Elongation at Break(50mm/min), %	ISO 527	≥600	858
Tensile Strength at Yield(50mm/min), Mpa	ISO 527	≥8	12.9
Melting temperature (DSC), ℃	ISO 11357	≥120	125
Vicat Softening temperature A50, (10N), ℃	ISO 306	≥85	103
Water content, %	ISO 15512	≤0.1	0.06
Hardness, Shore D, HD	ISO 868	≥50	56
Peeling Strength (3 Layer) (23℃), N/cm	ISO 21809-1	≥150	240
Peeling Strength (3 Layer) (50℃), N/cm	ISO 21809-1	≥130	150
Peeling Strength (3 Layer) (80℃), N/cm	ISO 21809-1	≥30	50

Extrusion

L-5REN2 can be applied by flat die or crosshead extrusion. The actual extrusion conditions will depend on the type of equipment used and the size of the pipe. The following conditions may be used as a guideline when starting up the extruder:

Item	Feeding Zone	Middle Zone	Transition Zone	Mould Head	Melt Temperature
Processing Temperature（℃）	150～180	190～220	190～220	200～220	190～220

Fusion Bonded Epoxy (FBE), EN 301A

EN 301A is a thermosetting epoxy powder coating system that was engineered to protect pipelines from corrosion in the most demanding operating environments. EN 301A is designed to be used as a primer layer for 3LPE or 3LPP system.

This product has been certified to meet the requirements of CSA Z245.20-18 standard.

Powder Properties

Characteristic	Acceptance criteria	Test Standard
Color	Green	Visual Color-Pass
Moisture Content (%)	<0.5%	CSA Z245.20 Section 12.4
Particle Size	Larger than 250 µm <0.2% Larger than 150 µm <3.0%	CSA Z245.20 Section 12.5
Density (g/cm3)	1.45±0.05	CSA Z245.20 Section 12.6 CSA Z245.20 Section 12.6
Thermal Properties	Tg2: ≥98℃	CSA Z245.20 Section 12.7
Thermal Properties	ΔH=45±10J/g	CSA Z245.20 Section 12.7
Gel time (200℃ s)	20±5	CSA Z245.20 Section 12.2
Cure time (230℃, min)	≤3min	CSA Z245.20 Section 12.7

Film Properties

Characteristic	Acceptance Criteria		Test Standard
Cathodic Disbondment	48 Hours, -1.5 volt, 65℃ 28 Days, -1.5-volt, 23℃	2.5 mm Average 3.0 mm Average	CSA Z245.20 Section 12.8
Flexibility	bending, -30℃,3°	No Cracking	CSA Z245.20 Section 12.11
Impact Resistance	1.5 J, -30℃	No Holidays	CSA Z245.20 Section 12.12
Hot Water Resistance	48 Hours, 75℃	1 Rating	CSA Z245.20 Section 12.14
Thermal Properties	ΔTg ,℃	\|ΔTg\|≤5	CSA Z245.20 Section 12.7

Preparation of the specimen

Abrasive blasting to Sa2.5 near-white metal with surface profile of 50-100 microns. Then, clean the surface with high pressure gas
Put the specimen into the oven (200℃), preheat 40-50min
Spray the powder to the preheated specimen with electrostatic spray gun, then place it in the oven, keep it there for 5-10 minutes at 200℃, then cool it to room temperature.
The dry film thickness should be 350±50µm

Specifications

Surface Preparation	Remove all surface contamination before abrasive blasting. Blast clean using steel grit to Sa2.5 near-white metal with a minimum surface profile of 50-100microns.
Application	Factors such as plant capability, specifications, and pipe construction or characteristics can affect application conditions. The recommended application temperature range for 3PE 3PP systems is 180-220ºC.
Recommended Film Thickness(µm)	120~350μm
Storage	1. The product should be stored in a cool, ventilated, dry room with temperature below 30℃ and humidity below 65%. 2. Keep away from fire and heat and tide. 3. After use, it should be sealed in time to prevent powder from being been polluted and damped. 4. Reduce the number of movements to avoid impact and pressure. 5. The maximum stacking height should not exceed 5 layers.
Package and Handling	The package is a 25kg box, lined with polyethylene plastic bags. During shipment, it should be loaded or unloaded lightly and avoid direct sunlight, heat, and moisture.
Shelf Life	12months
Theoretical Coverage	0.69 m²/kg/mm

Polyethylene Coating, EJ-EN8

EJ-EN8 is a polyethylene topcoat for the three-layer coating systems, in granule form. The product is also available in powder form. The product is suitable to operate in the temperatures from -45 C up to + 89 C.

EJ-EN8 complies with international standards, such as ISO and CSA, when appropriate industrial manufacturing standard procedures are implemented, and a continuous quality system is present. EJ-EN8 is best used in combination with L-5REN2 adhesive and a compatible FBE, such as EN 301A.

Characteristic	Testing	Requirement	Typical value of EJ-EN8
Density of the base resin, g/cm³	ISO 1183	≥0.930	0.947
Melt Flow Rate (190℃, 2.16Kg), g/10min	ISO 1133	≥0.17	0.45
Elongation at Break, %	ISO 527	≥600	858
Tensile Strength at Yield, Mpa	ISO 527	≥15	16.9
Melting temperature (DSC), ℃	ISO 11357	≥125	129.5
Vicat Softening temperature A50, (9.8N), ℃	ISO 306	≥110	116
Water content, %	ISO 15512	≤0.05	0.0028
Hardness, Shore D	ISO 868	≥55	58.5
Oxidation induction time, min	ISO 11357	≥10	15
Environmental Stress Crack Resistance (F50, Condition A), H	ASTM D1693	≥1000	1100
UV Resistance and thermal aging, %	ISO 21809-1	ΔMFR≤35	20
Carbon Black Content, %	ASTM D1603	≥2.0	2.2

Extrusion

EJ -EN8 can be applied by flat die or crosshead extrusion. The actual extrusion conditions will depend on the type of equipment used and the size of the pipe. The following conditions may be used as a guideline when starting up the extruder:

Item	Feeding Zone	Middle Zone	Transition Zone	Mould Head	Melt Temperature
Processing Temperature, ℃	130～180	220～240	220～240	220～240	200～240