Case Study: Solving Adhesion Failures in the Manufacturing of 5G Telecom Masts

Clients

Typical clients in this sector include:

  • Telecom Infrastructure Manufacturers
  • Engineering & Fabrication Firms
  • Structural Steel Suppliers
  • Utility and Communications Contractors

These clients require systems that provide:

  • Strong adhesion to galvanised substrates
  • Efficient brush and roller application
  • Water-based, low-odour technology for open environments
  • Long-term corrosion protection in exposed locations

Scope of Work

This project involved addressing ongoing coating failures on 5G telecom masts. The
original coatings were peeling away from the galvanised surface, causing unnecessary
rework and wasting both time and money.

The process included:

  • On-site assessment with the engineering team
  • Identification of substrate compatibility issues
  • Selection of appropriate adhesion primer and topcoat
  • On-site guidance to ensure application success

All work was carried out in a busy production area using brush and roller, requiring
low-odour, easy-to-apply systems that didn’t disrupt other operations.

Paint Types

New Guard Coatings recommended a specialist water-based system optimised for
galvanised steel:

  • Multiprim – A water-based adhesion primer, specially formulated for difficult
    substrates. Tintable, fast-drying, and brush/roller friendly.
  • RD Monoguard – A high-performance, single-component acrylic topcoat. Offers
    C5 corrosion protection, excellent durability, and is available in a wide range of
    colours.

This combination ensured not only optimal adhesion but also a durable and attractive
finish on each mast.

Highlight: Multiprim & Monoguard System

This tailored coating system delivered immediate and long-term improvements:

  • Outstanding Adhesion – Multiprim bonds strongly to galvanised surfaces, solving
    historic peeling issues
  • Corrosion Resistance – Monoguard provides long-lasting C5 protection, ideal for
    exposed telecom structures
  • Application Friendly – Suitable for use with brush and roller in open factory
    settings
  • Custom Colours – Monoguard can be tinted to align with customer branding or
    project needs
  • Water-Based & Low-Odour – Ideal for application in live environments without
    production downtime

The system was chosen not only for its technical performance but for its practicality,
giving production teams confidence and reducing disruption.

Substrate Compatibility

The manufacturer’s products are fabricated from hot-dip galvanised steel, a notoriously
tricky surface for coatings. Many generic coatings fail to adhere properly, especially
when applied without specialised primers.

Multiprim is specifically designed for this type of substrate, ensuring long-term performance when used in combination with the correct topcoat.

Coating System Structure

The system applied followed a straightforward, repeatable structure:

1. Preparation – Light mechanical cleaning of surface if needed

2. Priming – One full coat of Multiprim

3. Topcoating – One to two coats of Monoguard in the customer’s required colour

This easy-to-follow system allowed production teams to reduce time between coats,
while maintaining a consistently high finish.

System Benefits

Since switching to New Guard Coatings, the customer has experienced significant
benefits:

  • Zero Adhesion Failures – Eliminating the need to recoat and touch-up
  • Increased Productivity – Reduced delays means faster delivery timelines
  • Enhanced Appearance – A smoother, more professional finish improves
    perceived product quality
  • Lower Waste – Less product loss and fewer rejected units
  • Health & Safety Compliance – Safer working environment thanks to low-VOC,
    water-based systems
  • Trusted Support – Backed by New Guard’s technical expertise and site-level
    consultation

The customer now benefits from a streamlined coating process that saves time, reduces cost, and increases throughput, all without compromising quality or environmental standards.

Client Feedback

A senior contact on-site shared this reflection:
“Since using Multiprim and Monoguard, we've had zero issues with adhesion, even on galvanised steel. The colours look great, the application is smooth, and it's saved us a huge amount of time and hassle. Everything just works now.”

Conclusion

Whether it’s telecom masts, galvanised steel frames, or difficult-to-coat substrates, New
Guard Coatings delivers tailored solutions that solve problems, not just cover them up.
With proven product performance and hands-on technical support, manufacturers can
trust New Guard to deliver every time.
If you’re facing challenges with galvanised steel or need help refining your production
coating system, speak with a New Guard Coatings advisor today.

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