Powder coatings from FreiLacke
Corrosion protection with powder coatings
Corrosion is a ubiquitous problem that significantly impairs and shortens the service life and functionality of metal. An effective method of protecting against corrosion is to pre-treat the surface correctly and apply a high-quality, high-performance powder coating. FreiLacke offers specialised powder coating solutions that meet the highest standards and are also environmentally friendly.
High corrosion protection is important.
Corrosion can significantly reduce the structural integrity and functionality of metal structures. Effective corrosion protection is essential to minimise safety risks. In critical areas such as bridges, industrial plants or offshore platforms, unprotected steel can weaken the entire structure and lead to serious accidents.
Economic losses can also be avoided with good corrosion protection, as corrosion-related damage incurs high repair and replacement costs. Durable coating structures can significantly extend the service life of equipment, thereby reducing maintenance costs.
In addition, corrosion protection plays an important role in sustainability. Durable products help conserve resources and reduce material and energy consumption.
Powder coating:
Corrosion resistance for metals
Corrosion occurs when metals come into contact with oxygen and moisture – this process leads to oxidation and can cause long-term damage to materials.
Corrosion protection thanks to powder coating protects metals by forming a closed, resistant layer that prevents the penetration of water, salts or chemicals.
Powder coating is characterised by the following properties for corrosion protection:
UV and weather resistance
Ideal for outdoor applications such as façades, steel structures and vehicles
High chemical resistance
protects against substances such as acids and alkalis, which is particularly advantageous in the chemical industry or mechanical engineering
Abrasion resistance
Resists mechanical stress such as scratches and impacts and ensures a long-lasting appearance.
Particularly high-quality powder coatings such as those from FreiLacke offer additional protection through:
Dense, non-porous structure
prevents corrosion and chemical reactions
Multi-layer systems
optimise protection with special primers
High adhesive strength
provides long-lasting protection, even under extreme conditions
Coating process
The powder coating process itself involves electrostatically charging a dry powder coating, which is applied to the pre-treated metal substrate and then baked at high temperatures. This creates a durable, uniform surface that does not require the use of solvents – an advantage for both the environment and processing.
Thanks to electrostatic application, powder coating forms a homogeneous, flawless protective layer without air pockets or unevenness. In combination with appropriate pre-treatment, it ensures optimum adhesion to the metal substrate and long-term rust protection – including applications in C5 environments.
Advice from FreiLacke experts
Are you interested in FreiLacke’s powder coating solutions for your industry? Take advantage of the advice offered by our experts!
Corrosion protection classes
DIN EN ISO 12944 classifies corrosion exposure into different categories, which serve as a basis for selecting the appropriate coating system:
Corrosivity category | Beschreibung | Examples of typical environments |
|---|---|---|
C1 insignificant | very low corrosion load | heated buildings with neutral atmospheres, e.g. offices or hotels |
C2 low | low corrosion load | unheated buildings; anywhere where condensation can occur, e.g. warehouses and sports halls |
C3 moderate | moderate corrosion load | Urban and industrial atmosphere; moderate sulphur dioxide pollution and coastal areas with low salt contamination |
C4 strong | high corrosion load | industrial areas and coastal areas with moderate salt exposure |
C5 very strong | very high corrosion load | Industrial areas with extremely high humidity and aggressive atmospheres, as well as coastal areas with high salt exposure |
CX extreme | extreme corrosion stress | Offshore areas with high salt exposure |
FreiLacke has developed a two-coat powder coating system that meets the high requirements of corrosion protection.
The system consists of:
1. Epoxy primer
A modified epoxy resin that cures at object temperatures above 160 °C and offers excellent adhesion to the substrate and good mechanical properties.
2. Polyester, PS or PU top coat
A powder coating that cross-links at temperatures ranging from 140 to 180 °C, depending on the system, and produces coating films with excellent mechanical properties.
Industries and applications with high corrosion protection
Construction industry
Heavy-duty corrosion protection is essential in many industries. In the construction industry, bridges, high-rise buildings, industrial plants and steel structures are often exposed to extreme environmental conditions, making reliable protection a necessity.
Vehicle and mechanical engineering
In vehicle and mechanical engineering, commercial vehicles, agricultural machinery and industrial equipment are exposed to intense weathering, UV radiation, stone chips and chemicals (e.g. oils, alkalis, road salt). This is where coordinated system paint structures prove their worth, such as a corrosion-protective primer in combination with a highly resistant powder coating as a top coat for high impact and abrasion resistance.
Wind turbines
The energy and utilities sector also benefits: towers and nacelle components of wind turbines, transformer housings, electricity pylons and external pipelines receive long-lasting protection with reduced maintenance intervals thanks to such systems. Depending on the exposure class, coating thicknesses, pre-treatment and system paint can be specifically designed to ensure the required protection times.
FreiLacke – Your partner for powder coating solutions
With decades of experience in the development of powder coating systems, FreiLacke offers tailor-made solutions for demanding corrosion protection. Whether for the construction, automotive or mechanical engineering industries, our high-quality powder coatings meet even the most stringent requirements.
Visit our powder coating solutions and find out about our corrosion protection systems to find the optimal coating for your applications.
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