An Aluminum Roll with a Polysurlyn Moisture Barrier is a specialized industrial material designed for long-term corrosion protection. It consists of an aluminum coil that has been laminated with a multi-layer composite film, typically composed of polyethylene and a ionomer resin known as Polysurlyn, with a total film thickness of around 76 microns (0.076mm). This lamination is performed under high temperature and pressure at the factory, creating an exceptionally strong, inseparable bond. The primary function of this product is to protect the insulation layer on pipelines and vessels in demanding environments—such as refineries, power plants, and chemical processing facilities—from water vapor ingress and corrosive elements, thereby significantly extending the service life of the infrastructure.
Specifications and Alloy Grades
The aluminum substrate for these rolls is available in a range of specifications to meet various project requirements:
Thickness: Commonly ranges from 0.4mm to 1.2mm.
Width: Standard widths are from 500mm to 1500mm.
Alloy Grades: Key alloys used include 1060, 1050, 1100, 3003, and 3004, all selected for their inherent corrosion resistance. Alloys 1060 and 3003 are the most prevalent, accounting for 60-70% of usage due to their excellent balance of formability and durability. For highly aggressive environments like coastal areas or chemical plants with acidic atmospheres, the stronger aluminum-manganese alloys such as 3003, 3004, and 3A21 are preferred for their superior performance.
The Polysurlyn film itself is notable for its durability. With a standard thickness of 0.076mm and a weight of approximately 0.08 kg/m², the bonded film exhibits excellent toughness. Once laminated, it will not crack under normal handling and cannot be delaminated by hand, ensuring integrity during installation and service.
Robust Packaging Methods
To ensure the product arrives at the job site in perfect condition, robust packaging is critical. Hunan Green House Aluminum Industry Co., Ltd. employs tailored packaging solutions:
For large industrial rolls (weighing 2.5-3 tons), heavy-duty wooden pallets with a static load capacity of 5 tons are used to prevent deformation during shipping and handling.
For smaller rolls (e.g., 20-meter or 50-meter lengths), a comprehensive packaging method is used. This involves securing the roll on a wooden pallet, wrapping it in moisture-proof kraft paper and plastic film, and finally strapping it securely with steel bands. This multi-layer approach guarantees protection against physical damage, moisture, and contaminants during logistics.
Stringent Production Standards
The production of these rolls adheres to strict national standards to ensure consistent quality and performance:
Dimensional Tolerances: Controlled under GB/T 3880-2012, with thickness tolerance tightly maintained within ±0.02mm and width tolerance within ±2mm.
Chemical Composition: Conforms to GB/T 3190-2008 for the respective alloy grades.
Each roll is a certified qualified product. For a standard 0.5mm thick coil made from 1060 or 3003 alloy, the weight is approximately 1.355 kg/m², meaning one ton covers an area of about 738 square meters. The company offers flexibility, producing both small custom rolls (20-100 meters) and full-size master coils (2.5-3 tons).
Key Advantages and Performance Benefits
The combination of aluminum and the Polysurlyn film creates a superior protective jacketing solution with several key advantages:
Enhanced Corrosion Protection: The aluminum provides a robust physical barrier, while the Polysurlyn film offers an impermeable seal against moisture, preventing corrosion under insulation (CUI).
Exceptional Film Adhesion: The hot-press lamination process creates a permanent bond. Tests, such as soaking the laminated material in water for 24 hours, demonstrate that the film's adhesion and quality remain unchanged, proving its resistance to hydrolysis and delamination.
Long Service Life: This synergy significantly extends the lifespan of the pipeline insulation system, reducing maintenance costs and downtime.
Durability: The composite material is resistant to UV radiation, temperature variations, and physical impact, ensuring reliable performance in harsh outdoor and industrial settings