Protection Challenges in Heavy-Duty Environments

Construction and heavy machinery includes excavators, loaders, lifting equipment, forklifts and agricultural machinery. These machines face UV exposure, rain, mud, oil, chemicals and mechanical impact. Welded, complex and heavy structures require a balance of weatherability, corrosion protection, adhesion and mechanical performance.

Select the System by Corrosion Class and Service Life

    • General outdoor machinery: standard-durable polyester.
    • High-UV or long-term outdoor equipment: super-durable polyester.
    • More corrosive environments: heavy-duty epoxy primer with a polyester topcoat.
  • Veri Coating offers pure epoxy, heavy-duty epoxy, standard-durable and super-durable polyester systems.
  • Where TGIC is permitted, it normally offers a cost advantage at the same performance level.

ISO Corrosion Standards and Key Performance Indicators

  • Corrosion systems may follow ISO 12944 environment and durability categories.
  • Key tests include neutral salt spray, cyclic corrosion and scribe creep.
  • Outdoor topcoats focus on gloss retention and colour change after xenon-arc exposure.
  • Structural parts focus on adhesion, impact, bending and edge coverage.
  • Heavy-duty epoxy with a polyester topcoat can be designed and verified for C4-C5 environments.

Curing Risks for Heavy Parts and Welded Structures

Heavy sections may not reach the required metal temperature even when oven air temperature is correct, causing under-cure. Welds, sharp edges, deep recesses and shielded areas may have insufficient film build. Castings and hot-dip-galvanised parts can develop bubbles or pinholes if not fully degassed. Primer-topcoat systems also require controlled intercoat cure and recoat adhesion.

Future Trend: Longer-Life Corrosion Protection and Energy-Efficient Cure

Heavy-machinery coatings are moving toward higher corrosion classes, longer outdoor service life and lower curing temperatures. Future systems will place greater emphasis on primer-topcoat design, edge protection, curing control for heavy parts and total lifecycle cost.

Business Case

Low-Temperature High-Gloss Powder Coating for Compact Construction Equipment

Customer Profile

Shandong Luyu Heavy Industry, a leading global manufacturer of compact excavators and loaders, exports to more than 70 countries.

Applications

Compact excavators and loaders, mainly in orange, yellow and selected green safety colors, using solid-color high-gloss smooth finishes.

Project Summary

Supply has continued since March 2025, with monthly consumption of 50–80 tonnes and zero complaints. General industrial polyester-TGIC systems are used for domestic and non-European markets, while polyester-HAA systems are used for products exported to Europe.

Large components entering the yellow powder coating booth.

Requirements

Reduce curing energy consumption

Curing temperature of 150–160°C

High-gloss smooth finish above 90 GU

Consistent, saturated safety colors

Adequate film build on sharp edges and corners to reduce corrosion risk

Manual touch-up on yellow components to cover welds, corners and recessed areas.
Yellow loader buckets leaving the coating line.
Large components receiving a high-gloss smooth powder finish.
Cab components coated with focus on holes, welds and sharp edges.

Validation

Stable low-temperature curing at 150–160°C

Approximately 20% lower energy use than conventional high-temperature exterior polyester

Gloss consistently above 90 GU through higher resin content and gloss-enhancing additives

Average film thickness on sharp edges above 50 μm

Monthly supply of 50–80 tonnes with zero complaints to date

Stable powder deposition on yellow components in continuous production.
Cab components entering coating after silane pretreatment.
Yellow high-gloss coating on a Luyu loader.
Project team reviewing coating conditions and material use on site.
Orange high-gloss coating on a Luyu compact excavator.
Products Used:PT0S / PP1SPolyester-TGIC / Polyester-HAALow-Temperature CureHigh-Gloss SmoothOrange / Yellow / Green

Not sure which product fits your line?

Share your part mass, curing temperature, gloss target and sharp-edge protection requirements with our technical team.

Talk to a Technician