Why Fusion Bonded Epoxy (FBE) Tanks Are the Best Alternative to Zincalume & Galvanized Tanks
When it comes to water and liquid storage tanks, corrosion resistance, durability, and longevity are key factors. For years, Zincalume and Galvanized tanks have been the industry standard, but recent advancements in Fusion Bonded Epoxy (FBE) coatings offer a superior alternative.
But how do these materials compare in real-world conditions, especially in harsh environments with high humidity, salinity, or chemical exposure? One of the best ways to test this is through salt spray testing (ASTM B117)—a widely used industry standard for evaluating corrosion resistance.
In this post, we’ll explore:
✅ What salt spray testing is and why it matters.
✅ How FBE, Zincalume, and Galvanized coatings perform under extreme conditions.
✅ Why FBE-coated tanks are the best long-term investment for corrosion protection and durability.
What is Salt Spray Testing and Why is it Important?
Salt spray testing is a controlled corrosion test that exposes coated steel samples to a highly saline mist (5% NaCl) at 35°C (95°F) for extended hours. The goal is to simulate real-world exposure to coastal air, industrial pollution, and high-moisture conditions.
By tracking how long a coating lasts before red rust (steel corrosion) or white rust (zinc oxidation) appears, we can measure how effective it is in protecting against long-term deterioration.
Salt Spray Test Results: FBE vs. Zincalume vs. Galvanized Steel
| Coating Type | Coating Thickness | Corrosion Resistance (Red Rust Formation) | Coating Degradation (White Rust, Blistering, Peeling) | Expected Lifespan |
|---|---|---|---|---|
| Fusion Bonded Epoxy (FBE) | 250-500 µm | No red rust even after 3,000+ hours | No blistering, cracking, or white rust | 30+ years |
| Zincalume (55% Al-Zn coating) | 20-30 µm | Red rust appears between 1,000-1,500 hours | White rust appears early (~200-500 hours) | 15-25 years |
| Hot-Dip Galvanized Steel (HDG) | 70-150 µm | Red rust appears around 500-1,000 hours | White rust appears within 24-100 hours | 10-20 years |
1️⃣ Fusion Bonded Epoxy (FBE) – The Future of Corrosion Resistance
🔹 Best Performance: No red rust even after 3,000+ hours in salt spray.
🔹 No White Rust: Unlike Zincalume and Galvanized coatings, FBE does not oxidize or degrade over time.
🔹 Strong Adhesion: The epoxy fuses to the steel at high temperatures, ensuring a smooth, pinhole-free protective layer.
🔹 Chemical & Water Resistance: Perfect for potable water tanks, chemical storage, and extreme industrial applications.
✅ Ideal For:
✔ Coastal & high-humidity environments
✔ Industrial liquid storage
✔ Fire protection & potable water tanks
✔ Wastewater treatment facilities
2️⃣ Zincalume – Decent Corrosion Protection, But Not the Best
🔸 Moderate Performance: 1,000-1,500 hours in salt spray before rust appears.
🔸 White Rust Formation: Early signs of oxidation in high-humidity conditions.
🔸 Limited Self-Healing: Unlike Galvanized steel, it does not self-repair when scratched.
🔸 Not Ideal for Harsh Environments: Saltwater exposure accelerates pitting corrosion.
✅ Best For:
✔ General-purpose water storage
✔ Mild industrial environments
✔ Residential & agricultural applications
3️⃣ Galvanized Steel – Traditional but Vulnerable
🔹 Shortest Lifespan: 500-1,000 hours in salt spray before rusting.
🔹 White Rust in <100 Hours: Zinc reacts quickly with humidity, leading to premature oxidation.
🔹 Self-Sacrificing Coating: Once the zinc layer wears away, the steel underneath corrodes rapidly.
🔹 Prone to Flaking & Uneven Wear: Leads to weak points in the structure over time.
✅ Best For:
✔ Short-term, budget-conscious applications
✔ Low-humidity environments
✔ Basic rainwater harvesting
Why Fusion Bonded Epoxy (FBE) is the Best Choice
Compared to Zincalume and Galvanized coatings, Fusion Bonded Epoxy tanks offer the best long-term protection and the highest resistance to corrosion, chemicals, and extreme environmental conditions.
✅ Key Advantages of FBE-Coated Tanks:
✔ 3X longer lifespan than traditional coatings
✔ No rust, no degradation, no maintenance
✔ Eco-friendly, no heavy metal runoff
✔ Perfect for coastal, industrial, and potable water applications
📌 The Bottom Line
While Zincalume and Galvanized steel have been used for decades, they fail to provide long-term durability in harsh environments. Fusion Bonded Epoxy (FBE) tanks are the next-generation solution, offering unparalleled protection and cost-effectiveness over time.
If you’re looking for the best investment in water storage, Fusion Bonded Epoxy is the clear winner.
🔹 Interested in learning more? Contact us today to see how FBE-coated tanks can revolutionize your storage solutions! 🚀
