Plastisol Coated Steel Roll Forming Material Guide: PVC Coating, Coil Sizes & Heavy-Duty Uses

Plastisol Coated Steel Roll Forming Material

1. Overview of Plastisol Coated Steel in Roll Forming

Plastisol coated steel is a pre-painted steel material with a thick PVC (polyvinyl chloride) coating, typically applied at 100–200 microns. It is designed for maximum durability, impact resistance, and corrosion protection in harsh environments.

Unlike thinner coatings such as PE, SMP, or PVDF, Plastisol provides a heavy protective layer, making it ideal for industrial, agricultural, and coastal applications.

In roll forming, Plastisol coated steel is commonly used where mechanical protection and long-term durability are more important than high-speed production or tight forming radii.

2. Material Composition & Structure

Plastisol coated steel consists of:

Steel base (cold rolled steel)
Zinc or Aluzinc coating
Chemical pre-treatment
Primer layer
Plastisol (PVC) top coating
Backing coat

Layer Structure:

Steel core
Zinc or Aluzinc coating
Chemical pre-treatment
Primer coating
Plastisol (PVC) top layer (thick)
Back coat

3. Available Coil Specifications

Thickness Range

0.4mm – 2.0mm

Coil Width

600mm – 1250mm

Coil Weight

3 tons – 10 tons

Coil ID / OD

ID: 508mm / 610mm
OD: up to 1400mm

Tolerance

Good flatness
Slightly thicker surface layer affects forming

4. Mechanical Properties

Typical values:

Yield Strength: 180 – 350 MPa
Tensile Strength: 300 – 550 MPa
Elongation: 10% – 25%
Hardness: 100 – 180 HB

Grades:

DX51D
S320GD / S350GD

5. Coating Types (PLASTISOL SYSTEM)

PVC Plastisol Coating

Thickness: 100–200 microns
Back coat: 5–10 microns

Lifespan

15–25 years

Performance

Excellent impact resistance
Superior corrosion protection
High abrasion resistance
Good chemical resistance

Cost Level

Medium to high

6. Surface Finishes

Leather grain (very common)
Textured finishes
Matte finish
Anti-slip surfaces
Embossed patterns

7. Common Roll Forming Applications

Plastisol coated steel is used in:

Industrial roofing panels
Agricultural buildings (barns, sheds)
Wall cladding systems
Cold storage buildings
Coastal construction
Heavy-duty flashing and trims

8. Advantages of Plastisol Coated Steel

Very thick protective coating
Excellent impact resistance
Superior corrosion resistance
Ideal for harsh environments
Resistant to scratches and abrasion

9. Disadvantages / Limitations

Not suitable for high-speed roll forming
Limited performance in high UV exposure
Can fade over time
Heavier coating affects forming precision
More expensive than PE

10. Roll Forming Machine Considerations

Roll Tooling

Chrome plated rollers required
Larger radii recommended
Avoid sharp bends

Speed

8–25 m/min

Lubrication

Sometimes required

Cutting

Hydraulic or flying shear
Ensure clean cuts to prevent coating damage

Common Issues

Surface marking
Coating compression
Material drag in rollers
Build-up on tooling

11. Common Problems in Production

Surface marking from rollers
Coating deformation
Material sticking to rollers
Oil canning in wider panels
Edge cracking in tight bends

12. Pricing Guide

Typical global pricing:

Low: $1000–$1300 per ton
Medium: $1300–$1800 per ton
High: $1800–$2500+ per ton

Factors affecting price:

Coating thickness
Base material (GI or Aluzinc)
Finish type (textured vs smooth)
Supplier

13. Comparison with Other Materials

Plastisol vs PVDF

Plastisol = impact resistance
PVDF = UV resistance

Plastisol vs SMP

Plastisol = thicker coating
SMP = better color retention

Plastisol vs PE

Plastisol = much more durable
PE = cheaper

14. Best Industries Using Plastisol Coated Steel

Agriculture
Industrial construction
Coastal projects
Warehousing
Cold storage facilities

15. How to Choose Plastisol Coated Steel

Choose Plastisol When:

Harsh environments
Impact resistance required
Agricultural or industrial use
Heavy-duty applications

Avoid When:

High UV environments (consider PVDF)
High-speed production lines
Tight profile designs

16. FAQ Section

What is Plastisol coated steel?

Steel coated with a thick PVC layer.

Is Plastisol better than PVDF?

Depends — Plastisol is better for impact, PVDF for UV.

How thick is Plastisol coating?

Typically 100–200 microns.

Is Plastisol good for roofing?

Yes, especially industrial and agricultural roofing.

Does Plastisol crack during roll forming?

It can if bends are too tight.

17. Machine Matcher Section

We supply roll forming machines for all material types including Plastisol coated steel.

Custom-built machines to your profile
New machines built to specification
Global delivery available
UK and USA technical support

Contact:
Machine Matcher
Sales & Technical Team

Quick Specs

Thickness
0.4–2.0mm

Yield Strength
180–350 MPa

Coil Width
600–1250mm

Coil ID
508 / 610mm