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:

1. Steel core
2. Zinc or Aluzinc coating
3. Chemical pre-treatment
4. Primer coating
5. Plastisol (PVC) top layer (thick)
6. 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