51314-3906-Emerging Technology: Report on Development of an Enhanced Plastisol Coating System for Atmospheric Transitional and Soil and/or Water Immersed Applications on Steel Substrates.

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Product Number: 51314-3906-SG

ISBN: 3906 2014 CP

Author: Jon Brasher

Publication Date: 2014

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For the past seven years we have been testing a plasticized polyvinyl chloride formulation with the goal of developing and patenting an Enhanced Plastisol Coating (EPC) formulation and application System (EPCS) for the purpose of corrosion mitigation over a wide range of industries. Plasticized polyvinyl chloride on its own has been shown over decades of use to be durable and effective as an anti-corrosion coating [1]. Our research comparing EPC to widely used coatings along with testing by EPRI and other independent research facilities has shown that EPC performs well in atmospheric transitional and in water and/or soil immersed applications.In December 2012 the Alabama DOT completed a test of the EPC in Orange Beach Alabama. An EPC-coated galvanized steel post was placed in the bay at Perdido Pass for 13 months alongside a galvanized post. Results revealed that the EPC prevented rust and degradation at the splash zone and was impermeable to marine life below and UV above. In stark contrast the integrity of the galvanized steel post was severely compromised by red rust and pitting.Because the EPC requires heat to cure we have developed the EPCS to apply it. We found that EPC reacts with a specific type of infrared light within a certain wavelength range to achieve a cured state. The EPCS utilizes an array of infrared generators and moves over the substrate surface by way of a variety of drive systems. The EPCS has been demonstrated and proven to work on large smooth substrates applying a ? 62 mil EPC layer.In conclusion we believe the development of the EPCS provides multiple industries with a single effective coating for atmospheric transitional and immersion applications.[1] Corrugated Steel Pipe Institute Handbook of Steel Drainage and Highway Construction Products 2002 pp. 352-353