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← Return to Coating Solution Center Basic protection · 3-5 years

Anti-corrosion coating process for communication towers.Basis solution

Standard coating system for galvanized communication towers in mild to moderate corrosive environments. The XGE-920 gray primer + XGE-921 red topcoat form a two-coat protection system: XGE-920 provides excellent adhesion to galvanized surfaces, while XGE-921 offers both decorative appeal and long-term protection.

SubstrateHot-dip galvanized steel
SystemDouble Coating
primerXGE-920 Gray
topcoatXGE-921 Red
Protection Life3-5 years
corrosion environmentC3 / Medium
01

System Overview · Coating Structure

Standard communication tower corner steel structure, coating displayed from bottom to top.

Zn XGE-920 Grey Primer · 80μm XGE-921 Red Topcoat · 60μm Air ~30m 0m
XGE-921 Red TopcoatPolyurethane · Decorative + UV-resistant / Chemical-resistant
XGE-920 Gray PrimerEpoxy/Acrylic · Excellent adhesion to galvanized surfaces
Hot-dip galvanized substrateISO 1461 Galvanized layer
Total dry film thicknessPrimer 80μm + Topcoat 60μm ≥ 140μm

XGE-920 Gray Primer

Primer · Excellent adhesion to galvanized surfaces · Gray
Epoxy/Acrylic60-80μm dry filmgray

XGE-921 Red Topcoat

Topcoat · Decorative + UV-resistant / Chemical-resistant · Red
Polyurethane50-70μm dry filmRAL3020 Red
02

Construction phase process

Four-stage closed-loop management from substrate inspection to delivery

Phase One · Preparation

Substrate inspection

Verify the integrity of the galvanized layer; no white rust or oil stains, record the substrate condition.

Standards:ISO 1461 Galvanizing · Surface cleanliness ≤2 level
Phase Two · Surface Treatment

Polishing and cleaning

Light sanding/hand grinding to remove zinc salts, followed by dust removal with solvent wiping.

Tools:Wire brush / P120.Air source:No oil or water vapor
Phase Three · Primer

Spraying XGE-920

1-2 passes of airless spraying with a wet film thickness of about 120μm.

DFT: 60-80μm · Intercoat Interval: ≥6h / 25℃
Phase Four · Topcoat

Spraying XGE-921

1-2 passes of airless/regular spraying to achieve RAL3020 red color.

DFT: 50-70μm · Dry on surface in 2 hours / Drying time 24h
03

Detailed Construction Process

Critical steps + quality inspection points, rework automatically if unqualified

1
Substrate inspection: Integrity of galvanized layer (ISO 1461)
⚑ Quality GateIs the Galvanized Layer Intact?
↺ Re-inspection after zinc salt removal/relaying
2
Surface treatment: Scrubbing + solvent wiping
3
Surface cleaning: Oil-free compressed air dust blowing
⚑ Quality GateIs cleanliness met?
↺ Cleaning again
4
Sprayed Primer XGE-920 Gray · 60-80μm
5
Primer drying at 25℃ × 6h
⚑ Quality GateIs the primer film thickness OK?
↺ Repainting base coat
6
Sprayed Topcoat XGE-921 Red · 50-70μm
7
Topcoat drying time at 25℃ × 24h
⚑ Quality GateFinal Inspection Passed?
↺ Re-inspection after local patching
8
Delivery · 3-5 years of protection
04

Quality Control and Key Parameters

Inspection Items and Acceptance Standards at Each Quality Gate Checkpoint

Thickness of Galvanized Layer≥ 85 μm
Surface cleanlinessISO 8501-1 ≤ 2 level
Environmental Temperature/Humidity5-35℃ / RH ≤ 85%
Dry film thickness of primer60-80 μm
Thickness of the dried topcoat50-70 μm
Adhesion (Grid Test)ASTM 0-1 Grade
appearance / colorRAL 3020 · No Blistering
05

Key construction points

  • New galvanized parts:Natural aging time is 4-6 weeks, or apply the primer immediately after sanding.
  • White rust/zinc saltIt must be completely removed; otherwise, the adhesion of the primer will significantly decrease.
  • Airless spraying pressure: 15-20 MPa, fan overlap of 50%.
  • The primer must be completely dry before repainting to prevent blistering of the topcoat due to solvent retention.
  • Towers, bolts, and node plates in blind areas should be pre-coated first, then sprayed as a whole.
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