TSKNew Technology Information System (NETIS)
Registration No. KT-050045

Rust Prevention beyond Zinc Plating,with a Vivid Appearance
Modiﬁed saturated polyester resin coating

Toff-coated ProductsTOKYO ROPE MFG. CO., LTD.

Toff-coated products provide a new formof rust prevention.
Toff-coated products provide excellent resistance to corrosion, acid, and alkali,
through rust prevention processing that combines plating with modified saturated
polyester resin coating. They can last as long as 35 years in salt-susceptible areas, andmore than twice that in ordinary areas. In addition, they can be colored to blend in withthe surrounding landscape.

All tests have proven the superb performance of Toff-coated products.

1 Excellent basic physical properties

Saturated polyester resins have excellent basic physical properties (mechanical properties, resistance to ultraviolet
light, abrasion resistance, chemical stability, etc.).

2 Weather resistance (ultraviolet light and salt damage)In exposure tests on a beach of Miyake Island, Tokyo, the original heath remained almost intact after 16 years (accordingto Japan’s leading telecommunications company, NTT).

3 Resistance to scratches and high adhesivenessSalt spray tests, as done by scratching, have shown that Toff-coated products corrode more slowly than othercoatings tested, confirming its high adhesiveness (according to Japan’s leading telecommunications company, NTT).

4 Resistance to peeling and electrolytic corrosion

A construction field test of railroad rail fastening bolts/plates has revealed that Toff-coated products are moreresistant to peeling and electrolytic corrosion than all other products tested (according to Japan Railways Group).

5 Weather resistance (ultraviolet light and salt damage)〈Providing four times the resistant of zinc plating〉

Salt spray tests, accelerated weathering resistance tests, and soil-buried tests were conducted on steel sheets, steelbars, and bolts. Toff-coated products rank the best among the rust prevention methods tested (according toJapanese expressway company, NEXCO).

6 Weather resistance (ultraviolet light and salt damage)

Exposure tests were conducted on a coast of Okinawa Prefecture to compare rust prevention methods offered by all
suppliers of steel sheets and bolts. Toff-coated products were rated the best and fully adopted (according to theMinistry of Land, Infrastructure, Transport and Tourism and the Okinawa Development Agency).

7 Weather resistance (ultraviolet light and salt damage)Outdoor exposure tests and accelerated corrosion tests on steel sheets were conducted for rust preventive coatings.
As a result, Toff-coated products were rated as the best coating, equivalent to aluminum in rust prevention(according to the Steel Barrier Association).

,dhExposure Test of Toff-coated Rope on the Summit of Mt. Aso■Test outline
In February 2006, an exposure test was conducted, together with continual measurement of the concentration ofsulfurous acid and hydrogen sulfide gases on the summit of Mt. Aso.

Mighty net
Hachimantai City, Iwate Pref.
Kashima, Matsuyama
City, EhimePref.
【Gasgenerationconditions】

These gases are generated just under every other day on average.
netsulfurous acid (ranging from 0.5 toThe concentrations at the moment of gas generation were, on average, 10 Ropeppm forOkinoshima,City,Pref. sulfide.
25 ppm; figures above 25 ppm were rounded to 25 ppm), and 5 ppm (ranging from 0.5 toSukumo
23 ppm)forKochihydrogen(Okinoshima Circulation Line)

Note: Mountain climbing and sightseeing are prohibited at concentrations of 5 ppm or above for either sulfurous acid or hydrogen sulfide.

Pocket type rock net
Hotojima, Tsukumi City, Oita Pref.

【Corrosion conditions of exposed materials】
1.Exposed material (3x7, ropes of φ18 mm diameter)：
A.Three types of Toff-coated rope (coating on element wire in dark brown; coating on rope in dark brown/dark green)
B.Zn plating (material for comparison)
C.Zn-Al plating (material for comparison)
2.Results (see the photos below)(1) Toff-coated wires, after two years, were all satisfactory with no abnormality.
(2) The Zn plating, after half a year, formed red rust, which completely covered it in two years.
(3)The Zn-Al plating formed a thin layer of red rust in two years.
■At start of exposure test
Zn plating

Toff-coated(Rope coated in dark brown)

Toff-coated
Cover typerock net(Element wire coated in brown)
Hachimantai City, Iwate Pref.

Toff-coated(Rope coated in dark green)

Curtain net■After six months
Oga City, Akita Pref. (Oga-hanto Line)Zn plating【Red rust formed partially】

Toff-coated(Rope coated in dark brown)

Zn-Al plating

Windbreak fence
Myojin, Ikata-cho, Ehime Pref.
Guard cable
Fukushima City, Fukushima Pref.
(Bandai Azuma Sky Line)

Toff-coated(Element wire coated in brown)

Toff-coated(Rope coated in dark green)■After one year
Zn plating【Spreading of red rust】

Toff-coated(Rope coated in dark brown)

Toff-coated(Element wire coated in brown)

Toff-coated(Rope coated in dark green)

Hanging shelf
Doroyu, Yuzawa
City,twoAkitaPref.
■Afteryears

Zn plating
Flying ball blocknet【Complete covering of red rust】
Kasama City, Ibaraki Pref.

Zn-Al plating

Toff-coated(Rope coated in dark brown)【No abnormality】

Zn-Al plating【Thin layer of red rust】

Rock fence
Oga City, Akita Pref. (Oga-hanto Line)
Steel pipe pile type rock fence
Toyakocho, Hokkaido Pref. (Toya Park Toya Line)
Toff-coated(Element wire coated in brown)【No abnormality】

Toff-coated(Rope coated in dark green)【No abnormality】

Exposure Test of Toff-coated Rope on the Summit of Mt. Aso■Test outline
In February 2006, an exposure test was conducted, together with continual measurement of the concentration ofsulfurous acid and hydrogen sulfide gases on the summit of Mt. Aso.
【Gas generation conditions】
These gases are generated just under every other day on average.
The concentrations at the moment of gas generation were, on average, 10 ppm for sulfurous acid (ranging from 0.5 to25 ppm; figures above 25 ppm were rounded to 25 ppm), and 5 ppm (ranging from 0.5 to 23 ppm) for hydrogen sulfide.
Note: Mountain climbing and sightseeing are prohibited at concentrations of 5 ppm or above for either sulfurous acid or hydrogen sulfide.

【Corrosion conditions of exposed materials】
1.Exposed material (3x7, ropes of φ18 mm diameter)：
A.Three types of Toff-coated rope (coating on element wire in dark brown; coating on rope in dark brown/dark green)
B.Zn plating (material for comparison)
C.Zn-Al plating (material for comparison)
2.Results (see the photos below)(1) Toff-coated wires, after two years, were all satisfactory with no abnormality.
(2) The Zn plating, after half a year, formed red rust, which completely covered it in two years.
(3)The Zn-Al plating formed a thin layer of red rust in two years.
■At start of exposure test
Zn plating

Toff-coated(Rope coated in dark brown)

Toff-coated(Element wire coated in brown)

Toff-coated(Rope coated in dark green)■After six months
Zn plating【Red rust formed partially】

Toff-coated(Rope coated in dark brown)

Toff-coated(Element wire coated in brown)

Toff-coated(Rope coated in dark green)

Zn-Al plating■After one year
Zn plating【Spreading of red rust】

Toff-coated(Rope coated in dark brown)

Toff-coated(Element wire coated in brown)

Toff-coated(Rope coated in dark green)

Zn-Al plating■After two years
Zn plating【Complete covering of red rust】

Toff-coated(Rope coated in dark brown)【No abnormality】

Toff-coated(Element wire coated in brown)【No abnormality】

Toff-coated(Rope coated in dark green)【No abnormality】

Zn-Al plating【Thin layer of red rust】

Exposure Test in Severe Salt-susceptible Area for 16 Years
Time of installation: June 1988
Place of installations: NTT exposure test stationin Miyake Island, Tokyo.
Date of photographing: July 2003

■6 years after installationToff-coatedFluorine coating

Special urethane coating■16 years after installation

The Toff-coated products, as many as 16 years later, show almost no deterioration andadhesive force remains satisfactory.

Scene of Miyake Island test station

Outline of Japan Railways Group (JR) Corrosion Resistance Test

Materials compared: Epoxy and nylon■Test outline
Product name

Epoxy Nylon
Conventional product
Saturated polyester

Railroad rail fastening device; tie plate mounting bolts

Installation location Line section prone to electrolytic corrosion
Test period

June 1989 to February 1990

Test materials

From left in photo: conventional product, epoxy, nylon, and saturated polyester

Test result

Saturated polyester was the best.
Before installation

After period of test

Rail fastening device in installation

Basic Performance■Raw material test certificate
Measuring method

Specification

Limiting viscosity (dl/1)

Alternative value to the molecular weight measured by Uberoze viscometer

Toyobo method

0.83 to 0.87

Melting point (°C)

Measurement of melting temperature of polymer

DSC method

235±3°C

Specific gravity

Measurement by sink-float method

JIS K 5600

1.35±0.05

Item

Test name/description■Results of coating test (Conditions: coating after zinc plating)
Measuring method

Specification

JIS K 5600

No abnormality allowedAdhesive strength (N/mm2) Tensile test

JIS K 5600

≥ 15

Tensile strength (MPa)Tensile strength and elongation

JIS K 5600

≥ 50

Wear resistance (µm)

CS-10, 4.90 N, 1000 cycles

JIS K 5600

≤ 100

Pencil hardness

Pencil scratch value

JIS K 5600

≥ 2H

Item
Impact resistance

Test name/description
80-cm drop (300 g, 1-inch tip diameter)■Other properties
Measuring method

ResultCorrosion resistance

Item

Salt spray test method

Test name/description

JIS Z 2371

No rust or swelling for 6 months

Weather resistanceNTT outdoor exposure test in Miyake Island, TokyoJIS K 2381

No abnormality during period frominstallation to July 2003 (elapse of 16 years)

Immersion test in sea water 3 years, off the coast of Yokohama
Combustion gas ingredient
Detection of harmful components

Generation of harmful gas

̶

No abnormality

JIS K 7217

None

JWWA Z 108

All below criteria

JWWA Z 108: Leach test in accordance with Notification No. 45 by the Ministry of Health, Labour and Welfare (MHLW) based on the stipulationsin MHLW Ministerial Ordinance No. 15

TOKYO ROPE MFG. CO., LTD.
Head Office: (Nihonbashi Front) 6-2, Nihonbashi 3-chome, Chuo-ku, Tokyo 103-8306, JAPAN
Tel.+81-3-6366-7788
Fax.+81-3-3278-6870
URL: http://www.tokyorope.co.jp/english/
16-05-SA