The key to a successful pipeline anti-corrosion program is an effective protective coating system comprised of proven, high-quality coating materials, consistently applied to exacting specifications. Mill applied fusion-bonded epoxy (FBE) has been, and continues to be, the coating of choice for many pipeline operating companies since the 1960s. As the use of such coatings has expanded, much research has been conducted in an effort to improve the physical, chemical, and economic aspects of these coatings. New advancements in FBE coating technology have led to the availability of dramatically improved coating materials and systems to address specific pipeline construction needs and to enable the coating to function under a wide variety of corrosive conditions. In this paper, a review of FBE pipe coatings will be presented, progressing from their early years to the next-generation materials under development today. FBE coating solutions for the corrosion mitigation of pipeline systems will be discussed, ranging from its use as a stand-alone external coating, to the foundation layer of a three-layer coating, to a stand alone internal lining.
"FBE is dead. Long live FBE. ''1 FBE coatings have been in use for 40 years and, as such, are often mistakenly viewed as an established, unchanging technology. This couldn't be farther from the truth. FBE formulations of today are substantially different from their predecessors of even 5 years ago. Environmental conditions into which coated pipelines are placed and performance expectations have changed with time, often increasing in severity--however, FBE coatings have continuously evolved to meet these new challenges. The following sections will address the many applications of FBE in today' s pipeline industry (Figure 1), review its history as a corrosion mitigation coating, and explore new developments on the horizon.
FBE YESTERDAY
A fusion-bonded epoxy is a one part, heat curable, thermosetting epoxy resin powder that utilizes heat to melt and adhere to a metal substrate. It provides a coating with excellent adhesion, a tough, smooth finish resistant to abrasion and chemical degradation, and with the absence of entrapped solventsfl This combination of properties--particularly the ease of use and chemical durability--make FBE an ideal choice as a protective coating under a wide variety of environmental conditions. As a result, it is no coincidence that FBE coatings have been used for pipeline corrosion mitigation since 1960 on over one hundred thousand kilometers (sixty thousand miles) of coated pipe installed around the world (Figure 1). FBE is not only used on pipelines. Though not the focus of this paper, FBE coated reinforcing steel for concrete structures has been utilized since 1972 in over one hundred thousand concrete structures in North America alone) Corrosion costs an estimated three to four percent of gross national product for direct and indirect costs (Figure 2) in the developed countries of the world. 4 In order to minimize such costs, selection of the most economically effective technique for mitigating the effects of corrosion is a critical design decision. The protection of pipelines, valves, and fittings from corrosion is necessary to ensure long-term operation, minimize maintenance, and to prevent costly service disruption, loss of life, and injury. Protective measures are extremely important; yet, they represent a small fraction of the overall cost of a pipeline system. FBE coatings offer a solution to the protection of a wide variety of components in numerous applications. This is why they are the cornerstone corrosion protection defense in many gas and oil companies around the world. As will be seen FBE
