FIELD OF THE INVENTION This invention relates to the coating of metal objects, and particularly metal pipes, with specialized epoxy/polyolefin coating compositions.

BACKGROUND OF THE INVENTION Buried metal pipelines employed to convey liquids e.g. petroleum products including crude oil and petroleum gases, are susceptible to substantial corrosion due to the moist, often acidic or alkaline, environments of the soil in which they are buried. Methods have been devised to reduce pipeline corrosion, but none appear to have adequately solved this potentially very serious problem. Two different types of methods have been used to attempt to protect pipelines from corrosion, and have been used both separately and together. Cathodic protection from corrosion is provided by a procedure involving the application of an electric potential between the metal of the pipe and the material, e.g. earth, that surrounds the pipe. The second method involves placing one or more coatings upon the outer surface of the pipe so as to physically protect the pipe surface from the corrosive environments that may be encountered by buried pipelines.

Epoxy resin coatings have been used extensively for protection of pipe surfaces, and one such composition is shown in Warnken, U.S. Patent 4 009 224. Polyolefin coatings also have been used.

In Sakayori et al., U.S. Patent Re. 30 006, reissued 1979 May 22, a coating of a polyolefin modified by reaction with an unsaturated dicarboxylic organic acid or anhydride is applied upon a metal surface bearing a thin,

preferably 5-10 micron, primer coating of an uncured epoxy resin to improve adhesion of the polyolefin to the pipe.Japanese Kokai patent SHO 51[1976]-30863 of K. Nagai et al ^' , published 1976 March 16, describes the application of a polyethylene resin upon a cured epoxy resin coating that had been applied in powdered form to metal pipe. Japanese Kokai patent SHO 55[1980]-63221 of S. Aoyanagi et al, published 1980 May 13, describes the application to a thinly coated, partially-gelled epoxy primer upon a metal tube, of a spirally-wrapped carboxylic acid-modified polyolefin film. Japanese Kokai patent SHO 56[1981]-168862 of K. Iwaya et al, published 1981 December 25, discloses the application to a partially-gelled epoxy primer having a thickness of, for example 30-40 microns, upon a metal surface, of a mixture of a modified polyolefin having a melting point above 125*C and an unmodified polyolefin having a melting point below 125'C.

SUMMARY OF THE INVENTION

We have now found a process for the manufacture of a metal pipe having a composite pipe coating that exhibits good adhesion to the pipe, is resistant to cathodic disbondment and other modes of coating failure and resistant to physical damage of the type to which pipeline sections may be subjected to during construction and installation of a buried pipeline.

In the process of the invention for the manufacture of coated metal pipe, metal pipe of the type used, for example, in the manufacture of petrochemical pipelines is heated to a temperature of at least about 200*C. A powdered epoxy resin composition comprising an epoxy resin having a softening point of at least about 110'C, and a curing agent therefor, is applied to the hot

outer surface of the pipe, the resin composition melting and coalescing upon the hot pipe surface to form a coating having a thickness of at least about 300 microns _ _c __> and desirably in the range of from about 300 to about 800 microns; in a preferred embodiment, the epoxy resin composition has a softening point of at least about 90'C. Before the epoxy resin coating has completely cured, but preferably after it has gelled, an epoxy

10 resin-reactive polyolefin is applied to the hot outer surface of the epoxy resin; the epoxy-resin reactive polyolefin, which is referred to herein as modified polyolefin, is comprised of a polyolefin that has been grafted with an ethylenically unsaturated organic

15 carboxylic acid or anhydride.

The heat capacity of the metal pipe and the temperature to which it is heated prior to application of the epoxy resin composition desirably are such as to provide enough energy to sequentially (a) melt the

20 powdered epoxy resin and cause it to form a continuous coating upon the pipe surface, (b) melt and coalesce the subsequently applied modified polyolefin upon surface of the incompletely cured epoxy resin, and (c) then substantially cure the layer of epoxy resin. The

25 resulting composite coating adheres tenaciously to the metal pipe surface and provides the pipe with not only substantial resistance to cathodic disbondment but also with the ability to withstand substantial physical abuse and relatively high operating temperatures, especially when the modified polyolefin is modified polypropylene.

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Accordingly, the present invention provides a method of coating metallic pipe for use in buried pipelines to provide the pipe with resistance to impact damage and to cathodic disbondment, comprising:

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(a) heating the pipe to a temperature of at least about 200 ^* C;

(b) applying to the outer surface of the heated pipe a powdered epoxy resin composition comprising an epoxy resin and a curing agent therefor, preferably an epoxy resin composition having a softening point of at least about 90 ^* C, said powdered epoxy resin composition melting and coalescing upon the pipe to form a molten coating having a thickness of at least about 300 microns, and

(c) preferably after the epoxy resin composition has gelled upon the pipe surface but in any event before complete curing thereof, applying thereto a modified polyolefin, said modified polyolefin being a homopolymer or copolymer of hydrocarbon alpha-olefins having 2-10 carbon atoms and which has been grafted with an ethylenically unsaturated organic carboxylic acid or anhydride, the modified polyolefin forming an adherent and protective coating on the epoxy coating.

The present invention further provides metal pipe suitable for buried pipeline use and bearing an outer composite coating resistant to impact damage and to cathodic disbondment, said coating comprising an inner layer of a cured epoxy resin composition having a thickness of at least about 300 microns, and an outer coating of a modified polyolefin bonded to the inner layer, the outer layer having a thickness of at least about 300 microns.

The present invention also provides a method of coating metal pipe to be used in the construction of a" buried pipeline, comprising

(a) providing a heating station through which said pipe may be axially moved and heated to a temperature of at least about 200*C;

Figure 2 is a broken-away schematic view in partial cross section of a powder coating station employed in the apparatus of Figure 1.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

COATING MATERIALS

The powdered epoxy resin composition that is employed in the process and pipe of the present invention desirably employs an epoxy resin which is a polyglycidyl ether of a polyhydric phenol having a softening point

(Durrans') of at least about 90*C and preferably from about 90 to about 130 ^* C, and a curing agent for the epoxy resin. The preferred polyglycidyl ethers are those obtained from the condensation of bisphenol A

(2,2'bis(hydroxy- phenyl)propane) and epichlorohydrin.

Other polyhydric phenols which provide high melting polyglycidyl ethers include the phenol and o-cresol novolaks. Polyglycidyl ethers of the type described are available commercially e.g. from Dow Chemical Canada Inc. under the trade designation DER 663U, from Ciba-Geigy

Canada Ltd. under the trade designation GT 7074 and from

Shell Canada Products Ltd. under the trade designation

Epon* 2002, or may be made by extending a lower molecular weight epoxy resin with, for example, bisphenol A. The epoxy resins employed in the present invention are high melting solids and are curable at temperatures in the range of from about 180 to about 250* C. Any of the various known latent curing agents may be employed, and among these may be listed amines e.g. dimethylethanolamine and methylene dianiline, amides e.g. dicyandiamide, especially accelerated dicyandiamide, and phenolic resins.

(b) providing a first coating station in line with the heating station and capable of applying a powder coating to the exterior of the heated pipe;

(c) providing a second coating station in line with the first coating station for applying a subsequent coating;

(d) applying a powdered epoxy resin composition to the pipe as it passes through the first coating station, the resulting coating melting, coalescing and subsequently gelling upon the surface of the pipe to a thickness of at least about 300 microns;

(e) applying a modified polyolefin, preferably a powdered modified polyolefin, to the pipe section as it passes through the second coating station, the modified polyolefin forming a polyolefin layer having a thickness of at least about 300 microns, said modified polyolefin being a homopolymer or copolymer of hydrocarbon alpha-olefins having 2-10 carbon atoms and which has been grafted with an ethylenically unsaturated organic carboxylic acid or anhydride; the axial speed of the pipe through said stations and the distance between the first and second coating stations being adjusted to cause the polyolefin to be applied in the second coating station preferably shortly after gelation of the coating of the epoxy resin composition applied in the first coating station but in any event before complete curing thereof.

DESCRIPTION OF THE DRAWING:

In the embodiments shown in the drawings: Figure 1 is a perspective, schematic view of a portion of a pipeline coating apparatus; and

The epoxy resin compositions used in the invention may include flow control agents e.g. silicones an example of which is Modaflow* powder, pigments e.g. titanium dioxide, iron oxide and carbon black, fillers e.g. talc, calcium carbonate and mica, and other materials for the same purposes and effect as they are used in epoxy coating powders of the prior art. One example is a general purpose pipe coating of Dow Chemical Company that contains DER 642U epoxy resin (32 parts) ,

DER 672 epoxy resin (32 parts), curing agent (24.5 parts) , barium sulphate (8 parts) , red iron oxide (2 parts) and Modaflow Powder II (1.5 parts). Another example is a pipe coating resin from Shell Chemical

Company that contains Epon 2004 epoxy resin (78.2 parts),

Epon Curing Agent P-104 (3.1 parts), Epon Resin

2002-FC-10 (5 parts, contains 10% by weight of Modaflow flow control agent), red iron oxide (1.5 parts), barium sulphate (11.7 parts) and Cab-O-Sil* M-5 silica (0.5 parts) .

The powdered epoxy resin coating compositions may be manufactured by various methods known to the prior art; in a preferred embodiment, the coating compositions may be manufactured using a process in which the ingredients are melt blended, cooled and ground into a powder. Epoxy resin coating compositions of the type described are available commercially, and one such resin is sold by Valspar, Inc. under the designation D-1003LD.

In general, the epoxy resin compositions of the invention, for reasons which will become apparent below, exhibit gel times of from about 2 to about 20 seconds

(and preferably from about 5 to about 10 seconds) at pipe coating temperatures of about 250*C.

As used herein, gel time is defined as the time required for an epoxy resin composition to gel i.e. to exhibit a sudden increase in melt viscosity at a predetermined temperature. Gel time is measured by placing the epoxy resin composition on a hot metal surface, especially a hot plate, that is at the predetermined temperature. Using a spatula or other suitable device, a portion of the epoxy resin composition is drawn over the heated surface, to provide a sample having a thickness of approximately 200 microns. A sharp-edged object e.g. a paper clip, is then moved through the now molten layer of epoxy resin composition until a rapid increase in the melt viscosity of the composition is observed. The time, expressed in seconds, between when the epoxy resin composition is placed on the hot surface and the rapid rise in melt viscosity is the gel time.

It will be understood that the curing phenomenon of epoxy resin compositions involves chemical linking between polymer chains and that this linking (or

"cross-linking") mechanism is initiated almost immediately upon application (e.g. by spraying) of the powdered epoxy upon a hot pipe surface and continues as the epoxy resin composition melts, coalesces and gels.

After gelation, curing continues for a period of time e.g. about 90 seconds, that depends for instance on the temperature of the pipe, following the application of the powdered resin to the hot metal surface. Curing desirably is essentially complete within about 60 to about 180 seconds following application of the epoxy resin to the hot surface. Degree of cure may be measured by differential scanning calorimetry (DSC) using the procedure of the Canadian Standards Association (CSA) for fusion bonded epoxy resins para. 12.2 (page 28) . As an

example, the aforementioned epoxy resin composition

1003LD exhibits curing times of 50 seconds at 243*C, 60 seconds at 235'C and 70 seconds at 232*C.

The modified polyolefins employed in the invention are grafted homopolymers and copolymers of hydrocarbon alpha-olefins having 2-10 carbon atoms. For example, the polymers may be homopolymers or copolymers of ethylene, propylene, butene-1, 4-methyl pentene-1, hexene-1 and octene-1. The preferred polymers are homopolymers and copolymers of ethylene and propylene.

The polymers of ethylene may include hompolymers of ethylene and copolymers of ethylene with, for example, butene-1, hexene-1 and/or octene-1. The polymers of propylene may include homopolymers of propylene and copolymers of propylene and ethylene, including so-called random and impact grades of polypropylene. As will be appreciated by persons skilled in the art, such polymers may have a broad range of molecular weights if the polymer is to be applied to the pipe as a powder coating but a more limited range if the polymer is to be applied by extrusion techniques; both procedures of applying the polyolefin are discussed herein.

The polymer is modified by grafting with at least one alpha,beta-ethylenically unsaturated carboxylic acid or anhydride, including derivatives of such acids and anhydrides. Examples of the acids and anhydrides, which may be mono-, di- or polycarboxylic acids, are acrylic acid, methacrylic acid, maleic acid, fumaric acid, itaconic acid, crotonic acid, itaconic anhydride, nadic anhydride, maleic anhydride and substituted maleic anhydride e.g. dimethyl maleic anhydride. Examples of the derivatives of the unsaturated acids are salts, amides, imides and esters e.g. mono- and disodium maleate, acrylamide, maleimide and dimethyl fumarate.

Methods for the grafting of monomers onto polymers are known in the art, and include solution grarfting processes and melt grafting processes. Examples

.- of the latter are described in U.S. Patent 4 612 155 of

C.S. Wong and R.A. Zelonka, which issued 1986 September

16, and in U.K. patent applications No.s 88.027335 and

88.027336 of E.C. Kelusky, both filed 1988 November 23.

The methods for the grafting of monomers onto polymers

10 involve reacting polymer and monomer, usually in the presence of a catalyst e.g. an organic peroxide.

Examples of the latter include bis(tert. alkyl peroxy alkyl) benzene, dicumyl peroxide and acetylenic diperoxy compounds. The amount of grafted monomer is usually in

15 the range of 0.01 to 5% by weight of the polymer; in preferred embodiments, tha amount of grafted monomer is in the range of 0.1 to 2% by weight of polymer. The characteristics of the polymer subjected to the grafting reaction will depend on the characteristics required in

20 the grafted polymer that is to be coated over the epoxy

, resin composition, it being understood that some polymers, especially polypropylene, tend to undergo scission reactions in the presence of organic peroxides i.e _* in the grafting process.

_ Additional polymers and/or stabilizing agents e.g. antioxidants for example phenolic antioxidants, UV stabilizers and heat stabilizers, pigments e.g. titanium dioxide and carbon black, extenders e.g. mica and glass, rust proofing agents, fillers e.g. talc, calcium carbonate and mica, slip agents and flame retardants or the like may be added to the polymer either subsequent to the grafting process but prior to extrusion or other recovery of the grafted polymer from the apparatus used in the grafting process or in subsequent steps. For

_J___> example, ungrafted polymer that is identical to or

different from the polymer that has been grafted may be added to the grafted polymer. Toughening agents e.g. elastomers and very low density polyethylenes e.g. with densities below about 0.910 g/cm , may be added but such agents must be thoroughly dispersed in the polymer matrix. Other materials e.g. metal oxides or hydroxides, may also be added, especially in order to improve the adhesive characteristics of some grafted polymers, e.g. polypropylene.

COATING PROCEDURE

A preferred coating procedure of the invention involves the use of two powder spray stations spaced along the path of travel of a preheated section of metal pipe, the first station being employed to spray the powdered epoxy resin composition upon the pipe surface and the second station being employed to spray the powdered, modified polyolefin upon the incompletely cured epoxy resin surface. Techniques and apparatus for spraying powdered coating materials upon hot pipe surfaces are known in the art, and are described, for example, in J. Protective Coatings and Linings, May 1988,

Vol. 5, No. 5 p 26, by S.E. McConkey. In general, the powdered epoxy resin composition is entrained in an air stream and is directed by means of nozzles or jets against the hot pipe surface. A series of nozzles may be provided within a coating station through which lengths of preheated pipe are caused to pass. The nozzles may be positioned circumferentially of the pipe and spaced so as to provide a uniform coating of epoxy resin upon the pipe, or preferably are positioned on one side of the pipe with the coating composition being sprayed onto the pipe surface as the pipe, which is being rotated, passes axially through the coating station. A second, similar coating station is provided adjacent the first coating

station, the second station being adapted to spray onto the epoxy-coated pipe the powdered, modified polyolefin employed in the instant invention. The coating of the powdered epoxy resin or the powdered, modified polyolefin or both may be aided through the use of electrostatic coating procedures in which the powdered material is provided with an electric charge. The coating stations as thus described may be partially enclosed within appropriate housings to avoid the escape of resin particles and/or contamination of the epoxy resin powder or modified polyolefin powder by the other.

While the method of the present invention is described herein with particular reference to the modified polyolefin being applied to the epoxy resin coating in the form of a powder, the modified polyolefin may also be applied in the form of molten polymer e.g. using extrusion coating techniques. For example, the modified polyolefin may be applied by use of an annular die through which the pipe is passed or by so-called side extrusion in which a tape or film is extruded onto rotating pipe.

In the application of the coatings, a length of pipe to be coated passes axially and with optional rotation along a predetermined path sequentially through the coating stations. Before entering the first (epoxy resin composition) coating station, the pipe passes through a heating station where it is heated to an appropriate coating temperature in the range of from about 200 to about 250*C; this may be appropriately accomplished by means of induction heating, infra red heating or gas fired ovens. As the hot pipe passes through the two coating stations, which are aligned with the heating station and with each other, it receives sequential coatings of the epoxy resin composition and the modified polyolefin.

In preferred embodiments of the invention, the epoxy resin powder has a particle size of up to about 250 microns, especially in the range of about 10 to about 150 microns. Similarly, the modified polyolefin powder has a particle size of up to about 350 microns, especially in the range of about 75 to about 175 microns.

In further preferred embodiments of the invention, the epoxy resin powder has a melting point in the range of about 90 to 130 ^* C, especially in the range of about 95 to 125*C. Similarly, the modified polyolefin powder has a melting point in the range of about 105 to 175 'C, especially in the range of about 120 to 165*C.

The coating of epoxy resin has a thickness of at least about 300 microns, preferably a thickness in the range of about 300 to 800 microns, especially in the range of about 350 to 600 microns. Similarly, the modified polyolefin has a coating thickness of at least about 300 microns, for example 300 to 7000 microns, preferably a thickness in the range of about 500 to 1500 microns, especially in the range of about 550 to 1000 microns.

It is critical to the present invention that the modified polyolefin be applied to the epoxy resin-coated surface of the pipe before the epoxy resin composition has substantially cured; preferably, the polyolefin powder is applied immediately, i.e. within about 5 to about 60 seconds, after application of the epoxy resin composition, and desirably within about 15 seconds following application to the pipe of the epoxy resin composition. This careful timing feature may be controlled, among other things, by controlling the temperature and thermal mass of the pipe, the speed at which the pipe moves through the coating stations and the spacing between the coating stations.

In the drawing. Figure 1 schematically shows a portion of a pipe coating apparatus of the type employed in the present invention. It will be understood that the

_ entire pipe coating process employs various treatment stations both upstream and downstream from the apparatus shown in Figure 1. In a typical operation, stock lengths of pipe may be subjected to preheating, abrasive cleaning as by sandblasting and the like, sanding and grinding, and other surface conditioning operations before passing

10 to the apparatus shown in Figure 1.

A section of pipe is shown at 12 in Figure 1 and is conveyed along an axial path of travel shown by the arrow 14 by means of conveyor rollers 16. The latter may be positioned at an angle to the axis of the pipe so as

15 to impart an axial rotation to the pipe, as shown by the arrow 20. The section of pipe enters a heating station

18 in which the pipe is heated by various means such as passage through a gas fired oven and is thus heated to a temperature in the range of about 200-250*C. The pipe

20 then passes directly to an epoxy powder coating station

20. This station comprising a chamber having pipe entrance and exit ports and within which an epoxy powder of the type described above is sprayed upon the hot pipe surface. A schematic view of the chamber is shown in

25

Figure 2, the chamber including a supply ring 22 about the pipe 12, the supply ring having a series of radially inwardly oriented spray nozzles 24 adjacent one side of the pipe to direct epoxy powder against the surface of the rotating pipe. Supply and exhaust tubes 26, 28, are

30 provided to supply air-entrained epoxy resin composition powder to and to exhaust air from the chamber. In practice, the interior of the chamber becomes filled with a cloud of epoxy resin particles.

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Exiting from the epoxy powder coating station

20, the pipe passes to a polyolefin coating station 30 which is exemplified as a powder coating station and may be substantially identical to the epoxy powder coating station 20. In this chamber, air-entrained modified polyolefin powder is brought into contact with the hot surface of the epoxy-coated pipe and coalesces upon that surface to the desired thickness. The pipe exits the polyolefin powder coating station30, and curing of the epoxy resin coating layer continues as the pipe passes downstream in the direction of the arrow 14. If desired, an additional heating station 32 may be provided downstream from the polyolefin powder coating station, the station 32 typically employing infrared heating means to further heat and thus flow out the modified polyolefin layer. The pipe section 12 is then quenched and is subjected to rigorous inspection to insure integrity of the coating.

In a pipe coating operation, a typical speed of travel of the pipe section 12 along the path 14 may average about 24 feet (about 7.3 metres) per minute. If the polyolefin powder is to be applied to the epoxy-coated pipe within about 15 seconds following application of the epoxy resin composition, then the distance "d" between the epoxy powder and polyolefin powder stations must be approximately 6 feet (about 1.8 metres) . As noted above, it is preferable that the polyolefin powder be applied before substantial curing of the epoxy resin coating, but desirably after gelation. In practice, this can be accomplished by varying the temperature to which the pipe is heated, the linear speed with which the pipe passes through the coating stations, and the distance "d" between the epoxy and the polyolefin coating stations. Commonly, adjustments are made to the

axial speed of the pipe or to the distance "d" between the coating stations 20, 30, which may be made movable along the .axial path of travel 14 of the pipe so that the distance between them may be varied.

The thicknesses of the epoxy resin and the polyolefin coating will depend upon the flow rates of the respective powders to the pipe surface and the speed of the pipe through the coating stations. The flow rates of powdkred epoxy and powdered polyolefin may be adjusted as desired, as may the linear speed of pipe passing through the coating stations, the pipe speed, however, remaining strictly subject to the requirement that the polyolefin powder be applied to the epoxy resin composition layer before it has substantially cured but desirably after it has gelled.

An example of a typical pipe coating operation under the present invention may employ steel pipe having an outer diameter of about 12 inches (about 30.5 cm) and a wall thickness of 0.312 inches (0.78 cm). Using apparatus generally of the type described in connection with Figure 1, the pipe may be rotated and provided with an axial speed of about 24 feet (about 7.3 metres) per minute. Upon passing through the heating station 18, which may be a gas fired oven, the pipe may be heated to a temperature of 240"C. The pipe then immediately enters the epoxy powder coating station 20, epoxy powder being unifoirmly applied by means of a spray to the pipe surface and coalescing to form a wet film. The volume of epoxy resin composition applied is such as to provide a coating thickness of approximately 450 microns. The epoxy resin composition so applied may be that sold commercially by Valspar, Inc. under the designation D-1003LD, this powdered resin composition having gel time at 240*C of

about 4-8 seconds. The distance "d" separating the epoxy and polyolefin coating stations may be approximately 4 feet (1.2 metres), this distance providing approximately

10 seconds between the epoxy and the polyolefin coating steps. In this manner, the polyolefin is applied to the epoxy resin coating approximately 2-6 seconds after the latter has gelled but well before curing has been completed. The modified polyolefin powder is applied to the epoxy resin-coated pipe at a rate sufficient to coat the epoxy to a thickness of approximately 800 microns, the total composite coating thus having a thickness of approximately 1250 microns. The modified polyolefin so applied may be Fusabond D-139GBLK, manufactured by Du

Pont Canada Inc. The length of pipe 12 is supported a sufficient distance downstream from the modified polyolefin coating station so that the modified polyolefin coating has coalesced into a wet film and has cooled to a solid before contacting the downstream supporting rollers.

The resulting composite coating on the pipe is tightly adherent to the metal pipe surface and, because of the modified polyolefin outer coating, is highly resistant to impact damage or damage from rough handling. It has been found to be substantially impossible to physically separate the polyolefin coating layer from the epoxy layer at ambient temperature, the two layers being intimately bonded together. The thick epoxy resin coating layer provides the pipe with substantial resistance to cathodic disbondment and, together with the overlying polyolefin layer, serves to physically protect the pipe from damage of the type encountered in a pipeline laying operation.

Metal pipe commonly used in petroleum pipeline applications may have a wall thickness in the range of about 2-25 mm and an outer diameter in the range of about

2.5-150 cm; for example, when heated to coating temperatures in the range of about 240*C, such pipe has sufficient thermal mass i.e. it has absorbed sufficient heat energy, so that its surface temperature falls quite slowly. Unless quenched, the temperature of such a typical section of pipe heated to 240*C and then coated in accordance with the invention falls to 220*C only after about,,1-3 minutes. Thus, the more critical parameters involve the speed of the pipe through the coating stations and the space between the stations.

The present invention is particularly intended for the coating of pipe intended for use in petroleum applications. However, the coated pipe may have uses in other applications in which protection against cathodic disbondment is important.

While a preferred embodiment of the present invention has been described, it should be understood that various changes, adaptations and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims.