Pipelines are built to last, but internal corrosion is one of the biggest threats to their performance and longevity. Without reliable protection, deterioration can cause dangerous leaks, expensive repairs, and even pipeline failures—risks that operators can’t afford to take.
To combat these risks and reinforce pipeline integrity, operators utilize either traditional internal coatings or thermoplastic liner systems. While both create a barrier against corrosion and wear, they differ significantly in durability, maintenance, and overall effectiveness.
This blog breaks down the strengths and limitations of both options, providing a side-by-side comparison to help operators determine the best solution for pipelines that stand the test of time.
Understanding the Role of Internal Pipeline Protection
Pipelines are high-value assets, with construction costs ranging from $1.5 to $3 million per mile for oil pipelines and $2 to $5 million per mile for gas pipelines. With such a significant investment, maintaining pipeline integrity is a top priority. Internal protection is critical for preventing corrosion and ensuring pipelines operate safely for decades.
There are two primary approaches to internal pipeline protection:
- Traditional Coatings – Epoxy, fusion-bonded coatings, and coal tar enamel provide a protective layer inside the pipe, acting as a shield against corrosive substances.
- Thermoplastic Linings – Tight-fitting HDPE liner systems create a seamless internal barrier, preventing direct contact between the pipeline and transported materials.
Both methods are designed to improve pipeline performance, but factors like durability, ease of installation, and long-term maintenance set them apart.
What Are Thermoplastic Linings?
Thermoplastic linings, like United Pipeline Systems’ Tite Liner®, provide a seamless, high-performance barrier that protects pipelines from internal corrosion, abrasion, and chemical exposure. Unlike traditional coatings, which are applied as a surface layer, thermoplastic liners form a continuous, tight-fitting shield inside the pipeline, preventing transported materials from ever having direct contact with the pipe walls.
How Tite Liner® Technology Works
Tite Liner® technology utilizes a precise radial reduction process to install a tight-fitting HDPE liner within the host pipe. The process involves:
- Temporary Diameter Reduction – The HDPE liner pipe is compressed as it passes through a custom-fabricated roller reduction box, allowing it to fit inside the existing pipeline.
- Precision Installation – A winch system pulls the reduced-diameter liner through the pipeline section, ensuring a smooth, controlled insertion.
- Tight-Fitting Expansion – Once installed, the liner reverts to its original size, eliminating annular space and forming a secure, high-strength barrier.
By integrating with existing pipelines, Tite Liner® reinforces structural integrity and prevents internal corrosion without requiring full pipe replacement. Its tight-fitting design eliminates potential leak points, optimizing flow efficiency and ensuring long-term reliability. Additionally, Tite Liner® reduces reliance on chemical inhibitors and costly maintenance, making it a more cost-effective solution for extending pipeline lifespan.
What Are Traditional Coatings?
Internal coatings have long been used to protect pipelines, but their effectiveness varies depending on the environment, application method, and long-term durability. Below are some of the most common traditional internal pipeline coatings:
- Fusion-Bonded Epoxy (FBE) Coating – A thermoset polymer known for its strong adhesion and chemical resistance. Applied as a dry powder onto a preheated surface, it melts and cures into a uniform protective layer. FBE is widely used in environments requiring high durability.
- Three-Layer Polyethylene/Propylene (3LPE/3LPP) Coating – A multi-layered system combining an FBE primer, a copolymer adhesive, and a polyethylene or polypropylene topcoat. These coatings provide corrosion resistance and mechanical protection, making them suitable for some demanding environments.
- Coal Tar Enamel (CTE) Coating – A cost-effective thermoplastic coating applied in multiple layers, including a primer, coal tar enamel, and glass fiber wraps. While historically used for corrosion protection, CTE coatings require intensive surface preparation and have limitations in modern applications.
Key Drawbacks of Traditional Coatings
Despite their widespread use, traditional coatings have several inherent weaknesses that impact long-term pipeline integrity:
- Coating Defects (“Holidays”) – Small imperfections in the coating can expose the pipe to localized corrosion.
- Weld Joint Vulnerabilities – Coatings do not provide full protection at welds, leaving sections of the pipeline exposed to potential degradation.
- Limited Suitability for Small-Diameter Pipes – Some coatings cannot be applied efficiently to pipelines with smaller diameters.
- Weld Join Insert Sleeves Limitations – Extra installation costs, schedule delays, and the risk of failure from coating migration.
- Delamination Risks – If surface preparation is inadequate, the coating can separate from the pipe, leading to corrosion and leaks.
- Reduced Pipe Diameter – Epoxy coatings can shrink the pipe’s internal diameter, affecting flow capacity and pressure levels.
While traditional coatings remain a widely used solution, their susceptibility to wear, installation challenges, and maintenance requirements highlight the need for more advanced pipeline protection methods.
Side-by-Side Comparison: Thermoplastic Linings vs. Traditional Coatings
| Thermoplastic Liner (Tite Liner®) | Traditional Coatings | |
| Durability & Longevity | Long-term protection against corrosion, abrasion, and chemical exposure. | Susceptible to degradation, especially at joints and welds. |
| Installation & Maintenance | Fast installation with dedicated United Pipeline Systems crews.Long pull lengths for efficient deployment.Minimal maintenance is required. | More time-consuming application process including factory application and field application of weld joint protection.Requires frequent inspections and touch-ups. |
| Cost-Effectiveness | Lower total cost of ownership due to fewer repairs and longer lifespan. | Higher costs over time due to degradation and increased maintenance and repair. |
| Leak Prevention & Pipeline Integrity | Provide a continuous, leak-free solution. | Prone to failure at joints, requiring additional repairs. |
Why Choose United Pipeline Systems and Tite Liner®?
Internal corrosion is one of the biggest threats to pipeline longevity, making reliable protection a necessity—not an afterthought. United Pipeline Systems has spent over 40 years refining solutions that extend the life of critical infrastructure, with Tite Liner® installed across more than 30,000 miles of pipeline worldwide.
Designed to handle harsh operating conditions, Tite Liner® provides consistent, long-term protection without the maintenance demands of traditional coatings. Its precision installation ensures a seamless internal barrier, eliminating the weak points that coatings often leave behind. With a track record of success across industries, Tite Liner® offers a cost-effective way to reinforce pipeline integrity while minimizing downtime.See how our solutions have delivered real results in our Success Stories or reach out to United Pipeline Systems today to discuss how Tite Liner® can improve the performance of your pipeline infrastructure.