Protecting the exterior surface of underground pipelines from abrasion damage due to rocks, boulders, and above-ground traffic and equipment requires an abrasion-resistant outer layer or coating. An effective way to ensure an abrasion-resistant steel pipe involves applying a protective layer, like Polyguard IRO™ (Impact Resistant Outerwrap) and IRO™ HD (Heavy Duty) products.
Two less expensive ways to protect a pipeline from abrasion include using selective backfill and protective material laid over the pipeline before backfilling operations. A pipeline project engineer should determine the most cost-effective method for protecting your pipeline from abrasion damage, which can lead to expensive repairs and shutdowns.
An underground pipeline's external coating or layer must protect the steel against its primary threat - corrosion. To control corrosion, the outer coating/layer system must withstand environmental stresses due to scraping, erosion, scratching, etc., without suffering premature failure. Therefore, pipeline engineers, designers, and owners must consider abrasion resistance when choosing a pipeline’s outer coating.
Abrasion damage resulting in a loss of coating protection often displays as corrosion. An outer layer or coating without abrasion resistance can crack due to forceful impact or wear away with the constant flow of sand and water, which can expose the substrate to salt, and water, ultimately resulting in corrosion. In addition, above-ground traffic, equipment, and other impacts can crack the coating and leave the steel unprotected from corrosion.
Choosing an abrasion-resistant outer layer or coating that can withstand heavy-duty environments will provide the best way to protect your costly pipes from abrasion damage. Abrasion resistance will ensure the longevity of the coating system and lessening potential costs due to repairs and shutdowns.
Abrasion resistance refers to a coating’s ability to resist wear due to erosion or impact, and allow the system to continue providing comprehensive protection to the substrate. Generally speaking, hard, flexible, smooth, and thick coatings can best prevent coating wear by abrasion, impact, and erosion.
The coating must provide enough hardness to withstand an impact that could fracture the system down to the substrate.
The flexibility of the coating should prevent brittleness by balancing out its hardness.
A smooth coating will limit abrasion since it takes rough surfaces coming into contact with each other to create an abrasion.
It will take longer to wear a thicker coating down to the substrate than a thinner coat.
Abrasion-resistant Polyguard IRO™ (Impact Resistant Outerwrap, 0.013-inch thick layer) and IRO™ HD (Heavy Duty, 0.034-inch thick layer) protect a buried pipe's pre-approved field joint and mainline coatings (RD-6®, liquid epoxies, and Fusion Bond Epoxy (FBE), etc.) from abrasion damage for many applications, including:
Aggressive soil conditions
Thrust boring and microtunneling
Mainline coating protection
HDD (Horizontal Directional Drilling)
Field-applied ARO (Abrasion Resistant Overlay)
Air to soil transitions
Polyguard recommends using this system as a protective layer for field joints installed by a trenchless method that could impact a high consequence area (HCA) like a building, road, water, or populated place.
IRO™ and IRO™ HD provide numerous advantages and features that help an underground steel pipe's successful longevity and design:
Excellent flexibility, gouge, and impact resistance:
The IRO and IRO HD products eliminate the chance for costly spot repairs or re-pulling pipes. They also provide exceptional mechanical protection of the mainline coatings and underlying field joints.
IRO and IRO HD products incorporate fibers to improve the system's flexibility, gouge, and abrasion resistance while maintaining the resin's effectiveness.
It minimizes repairs.
Moisture-cured IRO™ and IRO™ HD do not need UV light or heating.
The system's simple application allows speedy coating protection and backfill.
IRO and IRO HD products permit pipeline operators to apply girth weld coatings at an ideal thickness to achieve optimum performance with the corrosion barrier.
IRO and IRO HD products produce smooth profiles to lessen damage during the pull-through.
IRO™ and IRO™ HD-controlled set times, packaging, and conformability help ensure efficient installations with consistent applications in any project environment.
It is essential to know that increasing the coating's thickness will reduce its flexibility and impact resistance.
Polyguard IRO™ and IRO™ HD work with cathodic protection (CP) systems for utilization according to DOT and PHMSA codes.
100-percent solids content
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Non-shielding and non-hazardous
Protecting the exterior surface of underground pipelines requires applying a superior abrasion-resistant outer layer or coating, like Polyguard IRO™ (Impact Resistant Outerwrap) and IRO™ HD (Heavy Duty) products. Our outer layer products protect underground pipelines, mainline coatings, and pre-approved field joints from abrasion damage. Furthermore, our simple-to-install systems provide excellent flexibility, as well as gouge, and impact resistance.
In the realm of industrial systems and infrastructures, pipes play a pivotal role. They’re relied on to be efficient in the transportation of fluids and gases needed for processes.
Whether it’s water distribution, chemical processing, or managing corrosive substances, choosing the most suitable material for pipes is a decision that carries implications.
Here we’ll delve into the application considerations for industrial pipes. Namely, the critical significance of material selection in ensuring performance, durability, and safety.
Industrial pipes are the unsung heroes that enable the smooth movement of substances across intricate networks.
These pipes are integral components of various sectors including chemical processing plants, water treatment facilities, power generation plants, and more.
So the choice of material for these pipes holds tremendous consequences.
It directly influences the efficiency, integrity, and safety of the entire operation.
1) Corrosion Resistance:
One of the primary considerations when selecting pipe materials is their ability to resist corrosion.
Depending on the nature of the substances being transported, pipes must be able to withstand corrosive effects.
Corrosion not only compromises the structural integrity of pipes but also poses significant risks to the environment and human safety.
2) Temperature and Pressure:
The operational conditions of an industrial facility determine the temperature and pressure pipes will encounter.
Choosing a material that can handle these conditions without weakening, deforming, or failing is essential.
Careful consideration must to given to prevent accidents and ensure uninterrupted operations.
3) Fluid Compatibility:
Different materials can react with fluids in unique ways, affecting the purity and properties of the transported substances.
Compatibility is crucial to prevent contamination, reactions, or changes in fluid composition.
The right material choice can help with this.
4) Abrasion Resistance:
In situations involving abrasive materials or high-velocity flows, selecting a material with robust abrasion resistance is essential.
Failure to do so could lead to frequent maintenance, reduced efficiency, and increased costs.
5) Environmental Factors:
External elements such as weather conditions, exposure to UV rays, and potential interactions with soil should also be factored in when choosing pipe materials.
Selecting the right material for industrial pipes isn’t solely about functionality; it’s about safety, cost-effectiveness, and long-term sustainability.
Inadequate material choices can result in pipe leaks, bursts, or chemical reactions with potentially catastrophic consequences.
Ongoing maintenance, repairs, and replacements due to material inadequacies can significantly inflate operational costs.
For industries seeking a reliable, versatile, and cost-effective solution, Fiber-Reinforced Plastic (FRP) and Dual Laminate pipes shine. Their corrosion resistance, lightweight characteristics, and customizable properties make them prime candidates for a wide array of industrial applications. FRP pipes offer impressive strength-to-weight ratios and exceptional corrosion resistance, while Dual Laminate pipes combine FRP’s structural strength with the chemical resistance of thermoplastics.
Both FRP and Dual Laminate pipes provide exceptional longevity, reduced maintenance requirements, and enhanced safety for various industrial operations. Their capacity to withstand corrosive substances, extreme temperatures, and high pressures ensures dependable performance and long-term cost savings.
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