Newsletter #7 – High-Thickness Coating Solutions

10 March 2026

Engineering Protection for Extreme Environments

When standard coatings fall short, high-thickness coating solutions step in to deliver exceptional protection. Coatings exceeding 200 microns provide robust barriers against the most demanding operational conditions—extreme temperatures, corrosive chemicals, mechanical wear, high pressure, and electrical stress. At Tetrachim, we specialize in advanced coating technologies that ensure your critical components perform reliably in the harshest environments.

This newsletter explores our premium high-thickness coating solutions, including Rilsan® Fine Powders by Arkema, Teflon™ PFA and ETFE coatings by Chemours, Scotchcast™ epoxy powders by 3M, and Thermal Spray Powders by Saint-Gobain. We’ll guide you through application best practices and help you select the optimal solution for your specific needs.

1. High-Thickness Coating Solutions at Tetrachim

Rilsan® Fine Powders – Arkema
A bio-based thermoplastic coating offering excellent corrosion protection, flexibility, and chemical resistance. Rilsan® PA11 powders are particularly well suited for thick, uniform coatings when applied by dipping.
Teflon™ PFA & ETFE Coatings – Chemours
Fluoropolymers such as PFA and ETFE deliver outstanding chemical resistance, high-temperature stability, and low permeability. These coatings are ideal for severe chemical environments and can be applied in multi-layer systems using hot flocking to achieve high thickness with excellent adhesion between layers.

Scotchcast™ Epoxy powders – 3M
High-build epoxy powders like Scotchcast™ 260 provide excellent adhesion, edge coverage, mechanical strength, corrosion resistance, and electrical insulation. They are commonly applied by dipping, making them ideal for thick protective and insulating layers.
Thermal Spray Coatings – Saint-Gobain
Thermal spray technologies allow the deposition of very thick ceramic or metallic coatings, offering extreme resistance to wear, heat, corrosion, and pressure. These coatings are ideal when conventional polymer systems reach their limits.

High-Thickness Coating Solutions Comparison Table

Coating Technology	Typical Thickness	Max Service Temperature	Chemical Resistance	Mechanical / Pressure Resistance	Electrical Insulation	Other Advantages
Rilsan® Fine Powders applied by dipping	250–500 µm	90°C	Very good	Good	Very good	Flexible, bio-based
Teflon™ PFA coatings	200–1000 µm	260°C	Outstanding	High	Excellent	Non-stick properties
Teflon™ ETFE coatings	250–1000 µm	150°C	Excellent	High	Good	Tough, durable
Scotchcast™ epoxy powders	200-400 µm	180°C	Good	High	Excellent	Excellent edge coverage
Thermal Spray Coatings	200 µm– several mm	>800°C (depending on material)	Excellent	Very high	Limited (material-dependent)	Extreme wear resistance

2. Industry Applications for High-Thickness Coatings

High-thickness coatings are essential wherever equipment faces extreme conditions. From gas and chemical processing to power generation, mining, transportation, aerospace, water treatment, and food & pharmaceutical industries, these coatings deliver reliable protection against corrosion, chemicals, abrasion, high temperatures, and environmental exposure, while meeting the highest performance and regulatory standards.

Application Types and Main Benefits

Industry	Typical Applications	Benefits of High-Thickness Coatings
Oil & Gas	Pipeline internal & external protection, Valve bodies and stems, Downhole tools, Wellhead equipment ,Chemical injection lines, Subsea components	Extended service life in inaccessible locations Resistance to hydrocarbons, H₂S, saltwater, and erosion Robust barrier against multiple corrosive agents
Chemical Processing	Reactor vessels & internals, Heat exchangers, Piping systems, Valves and fittings, Pumps & agitators, Storage tank internals	Resistance to aggressive acids, bases, and solvents Reduced permeation and chemical attack Extended maintenance intervals and safe containment
Power Generation & Electrical	Bus bar insulation, Transformer components, Switchgear & distribution equipment, Cable accessories, Generator components, Electrical connectors	Superior dielectric strength and insulation Improved voltage breakdown resistance Protection from moisture, dust, and contaminants
Automotive & Transportation	Underbody protection, Fuel system components, Exhaust components, Brake components, Fasteners & hardware, Battery enclosures	Long-term corrosion protection Resistance to stone chips and road debris Improved durability and vehicle service life
Aerospace & Defense	Hydraulic systems, Fasteners & hardware, Antenna systems, Structural components	High reliability in extreme environments Wear, corrosion, and thermal protection Compliance with stringent aerospace standards
Water & Wastewater Treatment	Pipe internals & fittings, Valve bodies & gates, Pump components, Tank internals, Filtration equipment, Instrumentation	Long-term immersion resistance Protection from chlorine, pH extremes, and chemicals Reduced maintenance for critical infrastructure
Food & Pharmaceutical	Processing equipment internals, Mixing vessels & reactors, Conveyor components, Piping systems, Pharmaceutical reactors, Filling & packaging equipment	Excellent cleanability and chemical resistance Prevention of contamination Food-contact compliance

3- Processing & Application Tips for Successful High-Thickness Coatings

Surface Preparation: We cannot start any coating application without an adequate surface preparation (sandblasting, cleaning) to ensure adhesion to the substrate, especially for thick coatings. Apply coating shortly after preparation to prevent oxidation.
Layered Application: Very high thicknesses should be built using multiple layers to reduce internal stress. Apply multiple layers rather than one very thick layer. The use of hot flocking for coatings such PFA and ETFE enables thick layers build-up with excellent interlayer bonding and controlled thickness.
Fluid Bed Dipping Process for Rilsan® and Scotchcast™ powders: Ideal for achieving uniform, high-build coatings on complex geometries. Higher preheat temperatures produce thicker coatings.
Controlled Curing: Proper curing cycles are critical to achieve full chemical, thermal, and mechanical performance.
Thickness Monitoring: Regular measurement helps prevent defects such as cracking, pinholes, or delamination.

Proper material selection, surface preparation, and application technique are key to achieving maximum coating performance and service life. If you need help on how to select or process high thickness coatings, our team will be more than happy to assist you with our best tips tailored to your specific application.

Contact Tetrachim today to discuss your high-thickness coating requirements and discover how our advanced coating solutions can enhance the performance and longevity of your critical components.