Polysulfide Modified Epoxy Novolac Cladding for Steel Immersion/Splash Zone Service

An innovative concept of incorporating polysulfide links in epoxy novolac cladding systems through the use of a novel curing agent has been developed. This concept permits production of cladding materials exhibiting all the properties called for in thesolicitation for Phase I, such as¿ application by spray,¿ sag-free thickness of 4-5 mm,¿ crack-free thickness > 25 mm,¿ wash-out resistance after 20 minutes,¿ > 600 psi adhesion to Ultrahigh-Pressure Water Jetted (HP WJ) steel with cohesive failure mode,¿ 20% to 80% elongation,¿ weight loss in Taber Abrader < 30 mg @ 1000 revolutions,¿ < 0.5% weight gain after 168 hours of immersion in simulated sea water,¿ < 1 mm disbonded radius after 24 hours in the cathodic disbondment test,¿ 65% flat surface film thickness retained on edges,¿ 100% solids environmentally compliant (VOC, HAPs and toxic metal free).Phase II will be devoted to testing and optimization of the developed formulations, as well as to preparations for their commercialization. The extension of the life of protective claddings for the many billions of dollars worth of steel construction owned by the Navy that are subjected to splashing and tidal immersion in sea water will represent substantial repetitive annual savings for theNavy. In addition, similar installations belonging to other branches of the military and to civilian government organizations will reap similar benefits from using the new claddings. Many non-government civilian operations can also benefit. The significantperformance improvement involved will also open the possibility of additional export business to serve foreign entities and to better preserve operational effectiveness for all users. The use of readily available commercial raw materials produced in theUSA and the ease of application already indicated provide confidence that the economic attractiveness of the new cladding is assured.