Advancements in Enhanced Plastisol Coatings for Concrete Reinforcement: Application, Testing and Future Insights

Abstract Advancements in technology and formulation are allowing enhanced plastisol coatings (EPCs) to be applied to substrates that have never been considered in the past, whether due to size, location, or previous technological and economic constraints. Recent developments have increased both the ease and economic benefits of applying EPCs. Testing by the Electric Power Research Institute (EPRI)(1) has confirmed a 50-year service for EPCs, with strong resistance in harsh environments, as shown through rigorous ASTM(2) G85 Annex A31 and B1172 testing. This paper explores the advancements in EPC applications using induction and infrared systems and presents initial test results for EPC-coated concrete reinforcement, specifically in relation to concrete pull-out and bend testing. Early findings demonstrate the coating’s potential for extending service life and improving performance in concrete structures. Future testing of thinner applications will provide further insights into the coating’s behavior under structural loads.