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General Applications


In environments that stress the need for corrosive protection,
Gafco Industries coated products offer a high level of protection while maintaining a much more environmentally friendly final product than other coated materials on the market. The products used to create the coating are resistant to a vast variety of corrosive chemicals and when properly applied, provide an extremely strong shield from corrosive environments thus prolonging the life of expensive material and equipment.

In addition the Gafco Industries product line allows for bonding of couplings, on the job site for area needing extra protection of joints.

The coatings industry, as with countless other industries, has undergone many changes over the years. Pressures causing these changes include demands for more environmentally and health friendly technologies as well as higher performance and better chemical and corrosion resistance. Gafco Industries meets all of these emerging demands, cleanly.

Gafco Industries takes advantage of proven protective coating technologies based on functionalized polyolefin alloys. The proprietary compound provides exceptional adhesion to polar substrates, resulting in a highly versatile material that performs well in aggressive environments due to its flexibility and impact resistance properties. The material’s inherent toughness also provides resistance to abrasion, chemical attack and permeation by liquids. The coating material can be field repaired to near factory finish should damage occur without the use of dangerous or caustic chemicals.

Characteristics:

UV Protection

The unique chemical properties of the Polymer-based compounds provide un-surpassed UV corrosion protection when installed outdoors or exposed to sunlight and other UV producing environments. This means an extra layer of protection for long-term exposed installations.

Reduced Environmental Footprint

Unlike traditional PVC coated components and other coatings, tapes, paints, etc. Gafco Industries utilizes proven state of the art thermoplastic coating technologies that contain:

- No reactive ingredients

- No phthalates

- No halogens

- No isocyanates

- No heavy metals

- No VOC’s

- No Chlorine components

- No hydrogen chloride gas emissions resulting from burning

In addition to the many environmental and health advantages that Gafco Industries offers, it also provides the following additional beneficial characteristics:

+ Adhesion without primers

+ Chemical and galvanic corrosion protection

+ Low smoke and flame spread ratings

+ High di-electric strength

+ Superior flexibility without cracking at low temperatures

+ Superior mechanical, abrasive, and impact resistance

+ Superior finish

+ Light weight

+ Joint sealing

+ Food and water contact approved

+ Field repair ability

Use of functionalized polyethylene copolymers in construction and industry
Acceptance and uses of thermoplastic protective coatings are world wide, and growing. Their performance and environmental merits have been realized by numerous Government, military, and OEM users including local authorities like:

· Cal Trans (California Department of Transportation) Bridge components

· City and County of Denver

· CDOT (Colorado Department of Transportation)

Adhesion ASTM D 4541 >1,000 PSI

Hardness (Shore D) ASTM D 2240 55

Impact Resistance ASTM D 2794 >384 in./lbs.

Tensile Strength (psi) ASTM D 638 3482

Elongation ASTM D 638 498%

Salt Spray resistance ASTM B-117 >2,000 Hours

QUV ASTM G 53 2000 hours, no significant change, color/gloss

Tabor Abrasion ASTM D 4060 100 (mg loss CS 17 wheel)

Flexibility (conical mandrel) ASTM D 522 1/8 “, no cracks (greater than 32%)

Dielectric Breakdown ASTM D 149 893+- 163 volts/mil (at 20 mil, varies with color)

Volume Resistivity ASTM D 257 4.67 x 10 13 Ohms/cm

Flame spread index ASTM E-84 CLASS 1 or "A"

Smoke developed index ASTM E-84 CLASS 1 or "A"


Gafco Industries Internal Protective Coating
To enhance and impart additional corrosion protection, a 2 mil nominal lining of thermoset coating is applied and baked onto the interior of the
Gafco Industries coated products.

As with our external protective coating system, the internal lining uses environmentally advanced technologies that contain no VOC’s or other hazardous components as many competitors "urethane" based coatings.

Tested using ASTM D4518, our interior coating has proven to have a coefficient of friction a full 35% lower than standard coatings. This results in easier pulls with less chance of wire damage. The exclusive Gafco Industries "Easy-pull Glass-Coat Lining" can be a job saver when pulling cables.

· No VOC’s

· Baked on finish

· Low coefficient of friction

· Enhanced corrosion protection

The index of toxicity of the smoke generated is 1.78 according to test method NES 713. This is well below the Royal (British) Navy requirements of 5.

The index of toxicity of the smoke according to the test method BS 6853 used for projects in the London Underground is 0.21. This is well below even the most stringent requirement of an index of 1. Furthermore, the rate of generation of smoke and the density of the smoke are relatively low:

· The US Railroad requires that the smoke generated should be less than an index of 100 at 1.5 minutes, 200 at 4 minutes etc. The smoke index generated from Gafco Industries when burning is only 110 after 20 minutes.

· The smoke density index according to the test method BS 6853:1999 used for projects in the London Underground is 1.13 (A0 (ON)) compared to a requirement of 2.6.

Under BS 476, Gafco Industries Polymer Coatings can be considered to be Class 0 and, though not specifically flame retardant, more than meets the requirements for coatings in tunnels, enclosed buildings and on passenger trains.



Products

** All testing data available by request.
Only UL listed raw components are utilized prior to coating, insuring that top quality materials are the basis behind the finished product. This product is Listed to applicable UL Standards and requirements by Underwriters Laboratories Inc. The coating process does not disturb the overall zinc coating of the initial raw product thus ensuring the corrosive protection of the zinc coating remains intact. Proper cleaning and preparation of the product prior to coating guarantees proper adhesion. Additionally, the
Gafco Industries proprietary coating process provides maximum corrosion protection in extreme conditions.

GRC Conduit -All standard conduit trade sizes are available from 1/2" to 6"

IMC Conduit -All standard conduit trade sizes are available from 1/2" to 4"

Custom and Standard Nipples-All standard conduit trade sizes are available from 1/2" to 6"

FS/FD/GAUT Boxes- All standard configurations

Condulets - LB, T, LL, Form 35 - All standard trade sizes

Clamps, Straps, Hardware

Unistrut/Channel

Lighting Poles

Threaded Rod - All trade sizes

Enclosures - Disconnects, Switches, etc.

Special Projects/Materials are available upon request

*Standard exterior industry gray color. Custom colors available upon request.

*Thread protectors included with standard industry size-color coded aspects.

*Standard and custom lengths available on all products.

Performance in Fire Situations:

Gafco Industries coating materials are composed almost entirely on compounds of carbon, hydrogen, and oxygen. On burning, therefore, the fumes are principally made up of carbon dioxide and water. As a result, the toxicity of the fumes in a fire situation is extremely low, and while not specifically flame retardant, Gafco Industries more than meets the requirements for coating in tunnels, enclosed buildings, and on passenger trains. istorical use of Poly-Coatings


Project Historical use of Poly Coating

There are many applications where coatings are used ranging from electrical junction boxes and conduit to stadium seating and from cable supports to the coating of submersibles. The primary reasons why such coatings are used by the construction industry are the corrosion protection that can be offered as well as UV protection, beautification, and mechanical protection.

Pipe Coatings - Seattle

Thermoplastic coating is used by the Seattle Public Utilities for the protection of pipes and fittings in the often highly corrosive soils of Terminal 18 Re-development Project of Harbor Island. Inspectors examined the ductile iron pipe after five years and found it to be “as new”, while the PVC tape wrapped sections had already deteriorated. The project work has not only resulted in the thermoplastic coating being established as the coating standard for Seattle's water distribution mains, but also an increased demand across the United States.

Recent projects utilizing this process have included waste water plants in Snohomish Washington, and the Olympus Terrace Sewer District at Mukilteo Washington. Alaska Airlines uses thermoplastic coating on baggage racks.

Thermoplastic functionalized polyolefin alloys have been used for coating of water pipes for many years. On a project in Sweden using similar compounds, The Swedish Corrosion Institute dug up the pipes after 10.85 (15) years in the salty clay soils around Gothenburg. These are the results after 15 years:

Rusting – ZeroCracking – ZeroBlistering – ZeroFlaking – Zero

Adhesion - 100%

These results have indicated to the Gothenburg Water and Sewage Works a lifetime for the pipes in the ground of over 200 years . The experience in Sweden has spread to other parts of the world, principally, the UK, Australia, New Zealand and the Middle East.

These coating processes have also been used for their chemical and abrasion resistance in slurry and chemical pipes. They have been used in Washington and the Pacific North West in general for gas pipes and for the internal lining of sewage pumps and fittings carrying grit and gravel (see above). Again 1 and 3-year tests showed no wear at all.

The process is being evaluated for road culverts to carry salt and grit from the roadside in winter. It has been tested to ASTM A 926-94, which subjects a coated cylinder to a number of cycles in a mixture of salt and grit – like a washing machine. After one million cycles all other coatings – which included fusion bonded epoxy and galvanizing – were completely stripped. With thermoplastic technology, over half the coating still remained. No other coating met this performance!

Finally, this process is also used in automotive under-body applications, not only for the corrosion protection but also because they can pass stone chip testing at only 16 mils thickness. These coatings are now starting to be used and specified by Nissan, Renault and General Motors among others (SAE J400).

In summary the advances in thermoplastic coating products over recent years combined with the improvements in grinding technology have enabled functionalized thermoplastic powders to be more available for both fluid bed and electrostatic spraying. 12 years of laboratory testing and field experience has shown that such coatings really can provided very long term corrosion protection and abrasion resistance even in very harsh and salty environments as well as having the advantages of no Triglycidyl Isocyanurate (TGIC), no phthalates, no halogens, no VOCs, no isocyanates, and very low toxicity on burning .