Powercrete J: The Premier Two-Part Epoxy for Field Joint Protection

When it comes to protecting pipeline weld joints, not all coatings are created equal. In demanding applications like directional drills and road bores, the stakes are even higher. Abrasion resistance, adhesion, and long-term corrosion protection aren’t optional — they’re essential.

That’s where Powercrete J stands apart.  It was built for Directional Drills and Road Bores

In HDD (horizontal directional drilling) and road bore installations, pipelines are subjected to:

• Extreme abrasion during pullback

• High soil stress and friction

• Challenging environmental conditions

Powercrete J has earned its reputation as a premier two-part epoxy field joint coating specifically because it performs under these exact conditions. Its abrasion resistance and bond strength make it a go-to solution when the weld joint cannot be the weak link.

When you’re pulling thousands of feet through a bore, the last thing you want is coating failure at the weld.

Here’s something many people don’t realize:  Powercrete J isn’t just for HDD and road bores.

It’s also an excellent solution for standard field joints. Even in conventional installations, weld areas deserve the same level of protection as the factory-applied coating. Using a high-performance epoxy ensures continuity of corrosion protection across the entire pipeline.

If your pipe has been factory coated with Powercrete-DD, the recommendation is simple:

Pair it with Powercrete J for the field joints.

Powercrete-DD is widely recognized as one of the best abrasion resistant overcoats (ARO) on the market. And if your pipeline deserves that level of factory protection, it only makes sense to extend that same standard to the weld joints.

Powercrete J is available as a standard in:

• 2-pound kits

• 4-pound kits

Custom kit sizes are also available upon request, giving contractors flexibility depending on pipe diameter and project scope.

Want to See It for Yourself?

If you’re in the United States and would like to get your hands on a sample, let’s talk. There’s no substitute for seeing how a product handles in real-world conditions.

When it comes to protecting weld joints — whether in a challenging directional drill or a standard pipeline installation — Powercrete J delivers performance you can trust.

Because your pipeline deserves more than “good enough.”

Powercrete R95: THE High Build Epoxy

 

Product Spotlight: Powercrete R95 — A Field-Friendly High-Build Epoxy

When it comes to protecting field joints and targeted sections of pipe, crews need coatings that are tough, flexible, and practical to apply in the real world—not just in a lab. That’s exactly where Powercrete R95 shines.

Powercrete R95 is Henkel’s (formerly Seal for Life) high-build, novolac hybrid, two-part epoxy, engineered specifically for demanding field applications. Designed to perform in challenging environments, R95 is rated for continuous service temperatures up to 203°F, making it a strong choice for a wide range of pipeline and facility projects.

R95 can be used as a stand-alone coating, delivering robust corrosion protection on its own. It also plays well with others. Many operators use it as an additional protective layer over FBE or other epoxy coatings, adding extra insurance where conditions are especially aggressive or where coating damage is more likely.

One of the standout features of Powercrete R95 is its ability to be applied up to 30 mils in a single pass. Like all high-build epoxies, achieving that thickness does require some attention from the applicator—but fewer passes can mean faster application and fewer opportunities for defects.

Packaging is important in the field, and R95 checks that box as well. It’s available in:

• 2 lb kits

• 4 lb kits

• 50 ml repair cartridges

• Custom kit configurations

Powercrete R95 is one of the most field-friendly epoxies we’ve seen—whether you’re coating a field joint, touching up a damaged area, or handling small repairs without wasting material.

Powercrete R95 was designed with applicators in mind. It’s a reliable, flexible option for crews who need epoxy performance without unnecessary complexity.

If you’d like to learn more about Powercrete R95 or discuss where it fits into your next project, we’re always happy to talk.

Introducing New Powercrete Packaging Options: Efficiency, Sustainability & Faster Delivery

 New Powercrete Packaging Option

At Joint Specialists, we’re always looking for smart ways to improve how we deliver industry-leading coating solutions. Today, we’re excited to share an update: we’re in the final development stages of new foil packaging for Powercrete J, Powercrete R65/F1, and Powercrete R95 kits.

These new options will complement—not replace—our traditional packaging. Contractors and distributors will continue to have access to standard material formats, but now with additional choices that improve logistics, cost efficiency, and environmental impact.

What’s New?

We’ve engineered a modified blister pack and expanded our capabilities to include traditional foil pouches as well. Together, these flexible packaging formats open the door to a range of advantages for small and mid-size orders.

Do These Systems Offer Advantages? Absolutely.

1. Major Savings on Freight Costs

For smaller Powercrete kit orders, freight can get disproportionately expensive—sometimes shockingly so. Our new lightweight, compact packaging dramatically reduces dimensional weight, allowing us to ship far more economically without compromising product integrity.

2. Faster Delivery to Remote Job Sites

Construction schedules don’t wait, and neither should your materials. The reduced size and weight of these packages allow us to ship kits more quickly, especially to regions with 2–3 day transit times from our production facility in Conroe, TX. Faster shipping means less downtime, tighter schedule control, and increased project efficiency.

3. A More Sustainable Option

We’re proud to share that this packaging decreases plastic and cardboard waste by approximately 50%. As more companies prioritize environmentally conscious procurement, this provides a meaningful step toward more sustainable pipeline and coating operations—without changing your materials or application workflow.

Want to Learn More?

If you're interested in seeing a sample, exploring freight savings, or learning how this packaging could support your Powercrete needs, we’d love to talk.

Reach out anytime—our team is here to help.

Maximize Efficiency in the Field with Powercrete Custom Kits from JSI

Maximize Efficiency in the Field with Powercrete Custom Kits from JSI

When it comes to protecting pipelines and field joints, Powercrete has long been one of the most trusted names in high-performance epoxy coatings. Known for its excellent adhesion, chemical resistance, and long-term durability, Powercrete is a proven choice.

At Joint Specialists, Inc. (JSI), we’ve worked with Powercrete systems for decades — and we understand that the key to real-world success isn’t just in the coating itself, but in how it’s packaged, mixed, and applied in the field. That’s why JSI offers not only the full range of standard Powercrete kits, but also custom kit sizes designed to maximize efficiency and minimize waste on every project.

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The Full Range of Powercrete Products

JSI provides a complete selection of Powercrete epoxy coatings, each designed to meet specific field and factory coating needs:

• Powercrete J – available in 2 lb. and 4 lb. kits, ideal for field joints and repair applications where a high-build, 100% solids epoxy is needed.

• Powercrete R65/F1 – available in 1 lb., 2 lb., and 4 lb. kits, offering excellent performance for both onshore and offshore projects, with fast cure times and outstanding adhesion to FBE and steel.

• Powercrete R95 – available in 2 lb. and 4 lb. kits, providing maximum corrosion protection and mechanical strength in even the toughest environments.

Every kit is carefully proportioned and packaged for ease of use — ensuring that your crew can mix and apply Powercrete quickly and confidently.

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The JSI Advantage: Custom Kit Sizes for Real-World Efficiency

While the standard kit sizes meet most needs, JSI takes Powercrete a step further by offering custom kit packaging tailored to your exact project requirements.

Why does that matter?
Because in the field, efficiency is everything.

• Reduce waste – No more leftover material that goes unused or cures before it can be applied.

• Save time – Crews can grab the right-sized kit for the job instead of measuring or splitting kits in the field.

• Increase consistency – Each kit is perfectly measured, ensuring the correct ratio and performance every time.

• Improve logistics – Smaller or larger kits can simplify handling, shipping, and inventory depending on your project setup.

JSI’s flexibility in packaging means you get Powercrete coatings that fit your workflow, not the other way around.

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Why Powercrete Remains a Field Favorite

Powercrete products are formulated to deliver long-lasting protection against corrosion, impact, and abrasion. Once cured, they form a hard, glossy, and impermeable coating that bonds tightly to steel, fusion-bonded epoxy (FBE), and other substrates.

Key advantages include:

• 100% solids formulation – No VOCs or solvents.

• Exceptional adhesion and wetting properties.

• Fast cure times – ideal for quick backfill or recoating.

• Proven field performance across multiple decades and applications.

When paired with JSI’s custom kit options, Powercrete becomes even more efficient — helping you complete more work with less waste, in less time.

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Powercrete + JSI = Performance and Efficiency

At JSI, we’ve built our reputation on providing practical solutions that make field work easier, safer, and more cost-effective. Our ability to customize Powercrete kit sizes is just one more example of how we help contractors, owners, and applicators improve performance across the board.

If you’re looking for Powercrete J, Powercrete R65/F1, or Powercrete R95 — or if you’re interested in exploring custom kit sizes for your next project — reach out to the JSI team. We’ll help you get the right materials, in the right quantities, ready for the field.

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About JSI

Joint Specialists, Inc. has been serving the pipeline coating industry since 1995, providing proven materials and solutions for corrosion protection, joint coating, and field rehabilitation. From Powercrete epoxies to viscoelastic coatings and beyond — JSI delivers performance and reliability, every time.

Powercrete J Training Available

 Powercrete J

     JSI recently completed another successful job kickoff where Powercrete J is being used as the field joint coating not only for the sections of pipe that are part of the directional drilling section -- but Powercrete J is also being used for the standard drop in the ditch girth welds.

     Powercrete J has long been seen as the premier field joint coating for road bores and directional drilling applications out in the marketplace.  Powercrete J is also one of the three preferred coatings for Powercrete DD coated pipe (the other two being Powercrete R65/F1 and Powercrete R95). 

     If you and your company haven't evaluated Powercrete J lately, please reach out.  We would love to get you some samples to play with!  steve@jsicoatings.com

Powercrete Spotlight - Powercrete Varieties

 Powercrete Product Breakdown

From top to bottom:  J, R65/F1, R95

     In the Powercrete world, what once started as Powercrete-DD has (over time) expanded into an entire product line, offering multiple different product for many different pipeline operating conditions.  For a summary see below; but if you have questions:  much better to call or email:  936/321-3333 or steve@jsicoatings.com

Powercrete J 

The original!  When you think of Classic Coke (if you're old like me) it brings a certain sense of 'premium' with it.  Powercrete J is similar -- it is the original Powercrete product for coating field joints of lines that will be involved with road bores and directional drills; though it also excels as a standard field joint coating on non bore field joints. 

Powercrete R65/F1

This is the Powercrete product that is typically thought of as the "fast cure" or "cold weather" epoxy.  Available in 1 pound, 2 pound, 4 pound or custom kit sizes, Powercrete R65/F1 could be just what your project needs.

Powercrete R95

This is considered the Powercrete "high build" epoxy.  With 40 mils achievable in a couple of quick passes, Powercrete R95 is also approved for use on lines operating at elevated temps up to 95C.

Powercrete R120

A high temp, high build epoxy rated to 120C.

Powercrete R150

A high temp, high build epoxy rated to 150C

Powercrete repair cartridges

Powercrete R65/F1 is available in 50ml 1:1 cartridges that are perfect for completing pinhole and other small damage to any epoxy pipe coating.  

Powercrete Spray Cartridges

Powercrete R65/F1 is also available in 1:1 spray cartridges; with 400ml cartridges being the most common.  This product sprays absolutely beautifully.  

Powercrete for Field Joints

 Powercrete for Field Joints - Brief Summary

Powercrete R65/F1 is the FAST CURE epoxy option.  Available in 1#, 2# and 4# kits; we can also make custom kits to maximize efficiency and reduce wastage on your next project.

The original:  Powercrete J is the premier coating for your field joints that will be involved with road bores and directional drills.  Available in 2#, 4#, 10# and custom kit sizes.

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Powercrete R95 is the high build epoxy available in 2#, 4# and custom kit sizes.

Spray grade Powercrete R65/F1 is available in 400ml cartridges for spraying.  The same material is used in a 50ml repair cartridge (not sprayed).

We'd love to quote your next project; help you with technical information or make product recommendations.  Give us a call (936-321-3333) or shoot us an email:  steve@jsicoatings.com

Cold Weather Powercrete Product?

 Powercrete Pipe Coating for Cold Weather?

Powercrete R65/F1 Kits 

     When working with epoxy pipe coatings, especially in cold weather climates; "will this cure in cold weather" is an important question that needs to be asked.  In the Powercrete world - the fast cure epoxy that can be used in the coldest temperatures is Powercrete R65/F1.  We have a few factors here that tie in with "cold weather".

     First of all let's look at the "temperature of the actual epoxy kit" as an important key factor.  The temperature of the epoxy needs to be in the temperature range of 65-85F.  This generally means that the epoxy is kept out of the elements, inside a storage shed; in a truck with a heater running (if the weather is very cold) etc.  Below 65F the epoxy can become challenging to mix as the material will be very thick.  

    As a second point; the epoxy needs to be "above 40F" in order for the chemical reaction to occur.  This temperature can be impacted (and controlled) by preheating the steel, incorporating a tent of some kind, possibly incorporating a wind screen, etc.  Preheating the steel prior to application is always going to be a key factor in controlling your cure times.  If you are working with epoxy that has been stored at the right temperature --- and you have preheated your pipe --- and you are controlling the weather elements as well as you can --- then you can create an environment that is above that 40F temperature fairly easy in most (not all) parts of the country.

Efficiently Installing Powercrete on Field Joints

 Installing Powercrete on Field Joint Coatings in the Field

Powercrete R95 Hand Applied in the Field

     Whether you're hand applying Powercrete J, Powercrete R65/F1 or Powercrete R95, there are a few things your crews can be doing to be as efficient as possible in terms of labor costs and material waste.  I will divide these simple tips into two families:

1. Material Kit Size Selection
2. Crew Organization

     First:  selecting the correct kit size for your project.  This one is CRITICAL!  Every kit that is purchased will have a pot life that begins the very second it is mixed.  That pot life can vary, depending on what the ambient temperatures are outside, what the humidity levels are, what method was used to mix the epoxy, whether the kits were kept in a heated or cooled truck or trailer - etc etc etc etc.  All are huge factors.  We can't analyze all of those factors (or any of those factors) within this article really.  But we can look at the FIXED aspects of your project --- and analyze accordingly.

     What are the FIXED data points on your project?  You are working with a 16" pipeline -- AND -- the specification written by the owner of the pipeline indicates that the Powercrete product needs to be at least 30 mils thick.  I can see from my coverage chart that in terms of volume, 1.85 pounds of material are needed to coat one linear foot of 16" pipe at 30 mils.  That is actually a pretty nice fit.  Some of the material will end up on the ground; the coating will also be thicker than 30 mils in some places --- so to me personally - if your crews are reasonable experienced; one each 2# kit is likely the perfect size IN TERMS OF VOLUME. 

     But, with Powercrete J and Powercrete R65; you are very likely to need to put on to layers of epoxy and build up to that 30 mils.  Epoxy layers can't be "built" until the prior coat has reached the gel state.  So in that case - depending on your weather conditions - you may find in the field that working on two joints at a time works best.  You may find that you put the initial layer on the first joint with approximately half of the 2# kit.  Then you take the second half of that kit and you put a base layer on a second field joint.  You would then come back and mix a new kit to put the 2nd layer on both of those initial joints.  

    So in those cases where your crews will essentially 'coat two joints at once' -- you must make sure you have two joints welded, cleaned and preheated --- ready to go.  Otherwise you're going to have epoxy cure in the bucket during the downtime.  

How to check Powercrete Thickness?

 Powercrete J Thickness Test

This tool is critical when installing Powercrete

     Just about every specification for a pipeline coating out there in the world today is going to also supply the contractor with a coating thickness requirement.  In my experience, that often ranges anywhere from 20 mils to 60 mils (there are plenty of exceptions with most falling at 30-40 mils in my experience).  

     Why does the coating thickness matter?  Well, pipeline engineers are designed pipelines (including the coatings) with certain parameters in place around their project.  What is the soil like?  What is the backfill going to be?  What sort of abrasion and other forces are they expecting to see within a bore? 

     In addition, of course the coating thickness is a factor when considering things like the Tabor Abrasion tests.  The thicker the coating (within reason) the more abrasion a coating can withstand.  Thickness is IMPORTANT and all too often, the top of the pipe and the bottom of the pipe come up short.

    That is why crews in the field need a wet film thickness gauge as the first line of defense to help installers ascertain how their efforts to build thickness are going.  It is easy to get distracted out there -- you need a quick and easy way to see how thick your coating is during the installation process.  

    And if you have a crew who is just going to put the epoxy on as thick as they possibly can (material costs be damned) then keep this in mind:  many coatings have a MAXIMUM thickness.   When you exceed a coatings maximum thickness, you run the risk of introducing cracks in the coating.  

     So there you have it --- if you'd like one of these JSI wet film gauges, shoot me an email at steve@jsicoatings.com and I will mail one out to you!

Which Powercrete Product has the best Abrasion Resistance?

 Powercrete Field Joint Coating with Best Abrasion Resistance?

JSI Line Sheet - request a copy at steve@jsicoatings.com

    Powercrete coatings are highly regarded for their robustness and protective capabilities, particularly in safeguarding pipelines against various forms of damage. Among the suite of Powercrete products, Powercrete J stands out as a frontrunner in terms of abrasion resistance, boasting an impressive reported value of 1210 cycles per mil according to ASTM D4060 testing. This remarkable resistance to abrasion signifies its ability to endure prolonged wear and tear, making it exceptionally well-suited for pipelines operating in rugged terrains or environments prone to abrasive forces.

    Powercrete R65/F1 also offers commendable abrasion resistance, though slightly lower than Powercrete J, with a reported value of 1000 cycles per mil under the same testing standard. Despite falling just short of Powercrete J, Powercrete R65/F1 still provides robust protection against abrasion, ensuring reliable performance and durability in challenging conditions.

    Similarly, Powercrete R95 exhibits notable abrasion resistance, although its reported value of 850 cycles per mil places it below both Powercrete J and Powercrete R65/F1. Nevertheless, Powercrete R95 remains a formidable contender in pipeline protection, offering solid defense against abrasion and contributing to the overall longevity and integrity of pipelines.

    It's essential to emphasize that all three products—Powercrete J, Powercrete R65/F1, and Powercrete R95—deliver excellent abrasion resistance, albeit with slight variations in performance. While Powercrete J emerges as the top performer in this aspect, Powercrete R65/F1 and Powercrete R95 still offer significant advantages and are well-suited for applications where abrasion resistance is critical.

    Ultimately, the choice between these coatings depends on specific project requirements, environmental conditions, and budget considerations. Whether it's the unparalleled abrasion resistance of Powercrete J or the reliable performance of Powercrete R65/F1 and Powercrete R95, Powercrete coatings offer a range of solutions to meet diverse pipeline protection needs, ensuring long-lasting and dependable performance in challenging operating environments.

What is the difference between various Powercrete Coatings?

 How are Powercrete J, Powercrete R65/F1 and Powercrete R95 Different?

     Since its creation in the early 1990's, Powercrete products have seen a number of generations of products introduced to the marketplace.  The current batch of available products are significantly higher performing than the initial formulations that were introduced more than thirty years ago now.  I won't be discussing Powercrete-DD here; or Powercrete 410 (the newest factory applied ARO).  For the purposes of this article, I'm looking exclusively at the hand applied field joint coating options:  Powercrete J, Powercrete R65/F1 and Powercrete R95.  

     Looking at Powercrete on the whole, it is an epoxy coating that boasts many strengths.  Namely:

• All Powercrete products show fantastic adhesion to both bare steel and fusion bond epoxy.
• Powercrete products exhibit superior resistance to water immersion.
• In addition, Powercrete products offer industry leading mechanical properties for impact and abrasion resistance.
• Fast cure (Powercrete R65/F1) epoxy is available for quicker backfill.
• Powercrete kits (Powercrete R150) can be used on lines operating at up to 300F.
• Powercrete field joint coatings are the preferred method for coating field joints on pipelines utilizing Powercrete DD as an ARO. 

Powercrete J

Powercrete J Applications: Road Bores, Field Joint Coating, Bends, Fittings

     Powercrete J is the original stand alone Powercrete epoxy coating.  For many years, it has been seen in the industry as the #1 road bore epoxy coating for field joints on pipelines involved with road bores or directional drills.  Looking at some of the key technical data that shows how good Powercrete J is for the incredibly harsh conditions associated with a road bore:

• Adhesion to steel is >3000 psi using ASTM 4541
• Abrasion resistance tested with ASTMD4060 passes at 1210 cycles per mil
• Shore D Hardness comes in at 85
• CD is excellent 

Powercrete R65/F1 sometimes called Powercrete F1

Powercrete R65/F1 Applications: Road Bores, Field Joint Coating, Bends, Fittings

     Powercrete R65/F1 is the "Fast Cure" product in the Powercrete product line.  Available in 1#, 2# and 4# kits; this product is perfect for many different pipeline applications.  And don't let the "Fast Cure Powercrete" moniker fool you.  Powercrete R65/F1 still has excellent technical performance:

• Excellent Cathodic Disbondment performance at elevated temperatures (70C)
• Great impact resistance using ASTM G14
• Adhesion to steel under ASTM D4541 comes in at 3200 psi.
• Abrasion resistance comes in at 1000 cycles per mil using D4060.

Powercrete R95

Powercrete R95 Applications: Road Bores, Field Joint Coating, Bends, Fittings

     Powercrete R95 is known as the "High Build" Powercrete material.  Able to apply in thickness as high as 40 mils in a single pass, Powercrete R95 can dramatically reduce labor costs associated with "building" multiple epoxy layers in order to achieve the desired thickness.  It does that ---- AND brings in a strong technical performance:

• Adhesion to steel using ASTM D4541 comes in at 3500 cycles
• Abrasion resistance comes in at 850 cycles/mil
• Shore D hardness is 85
• Cathodic disbondment is right there with the results from Powercrete J and Powercrete R65/F1.  

     All in all - three EXCELLENT corrosion prevention solutions available today.  Proven performance.  

    If you have questions - please reach out immediately!  steve@jsicoatings.com   936/321-3333

Why are Powercrete J, Powercrete R65/F1 and Powercrete R95 such GREAT Coatings? 

For more info: steve@jsicoatings.com

Two-part epoxies are commonly used as pipeline coatings to prevent corrosion due to several advantageous properties they possess. Here are some reasons why two-part epoxies are considered good pipeline coatings:

1. Excellent Corrosion Resistance: Two-part epoxies exhibit exceptional resistance to corrosion, making them highly effective in protecting pipelines from degradation caused by exposure to moisture, chemicals, and other corrosive substances. The cured epoxy forms a dense and impermeable barrier that shields the pipeline from corrosive agents.

2. Adhesion and Bonding Strength: Two-part epoxies have excellent adhesion properties, allowing them to bond strongly to the surface of the pipeline. This ensures that the epoxy coating remains firmly attached, even in harsh environmental conditions or when subjected to mechanical stress.

3. Chemical Resistance: Two-part epoxies exhibit resistance to a wide range of chemicals, including acids, alkalis, solvents, and hydrocarbons. This resistance is crucial for pipeline coatings, as pipelines often transport various fluids that may contain corrosive elements.

4. Durability and Longevity: Two-part epoxy coatings are known for their durability and longevity. They can withstand prolonged exposure to UV radiation, temperature fluctuations, and other environmental factors without significant degradation. This long-lasting protection helps extend the lifespan of pipelines and reduces maintenance costs.

5. Flexibility and Compatibility: Two-part epoxy coatings are available in different formulations that can be tailored to specific pipeline requirements. They can be applied to a variety of substrates, including steel, concrete, and plastics, making them versatile for different pipeline applications.

6. Easy Application: Two-part epoxy coatings can be applied using various techniques such as spraying, brushing, or dipping. They have good flow and leveling properties, allowing for smooth and uniform coverage over the pipeline surface. The ease of application contributes to efficient coating processes.

7. Environmental Friendliness: Many modern two-part epoxy coatings are designed to be environmentally friendly, with low levels of volatile organic compounds (VOCs) and hazardous substances. This aspect is crucial for ensuring compliance with environmental regulations while providing effective corrosion protection.

Overall, the combination of excellent corrosion resistance, adhesion, chemical resistance, durability, and ease of application makes two-part epoxies well-suited for pipeline coatings. They offer reliable protection against corrosion, helping to maintain the integrity and safety of pipelines over their operational lifetime.

 Joint Specialists Pipe Coatings IN STOCK and READY to SHIP (March 2022)

     Joint Specialists has been a leading distributor of high quality pipeline coatings for more than two decades now.  Located in Conroe, Texas; JSI keeps a large inventory of material to support all of your pipe coating needs in our 20,000 square foot warehouse.  Below is a list of just a few of the different products we have available for immediate shipment.  Give us a call for pricing:  936/321-3333 or send an email:  steve@jsicoatings.com

Powercrete J:  Powercrete J is the premier two part epoxy coating for field joints on pipelines that will be involved with road bores and directional drilling applications.  Powercrete J is incredibly tough and has excellent resistance to the types of damage that can occur when a pipeline is dragged through a muddy hole.  Available in 2#, 4# and 10# kits, we have Powercrete J available in any quantity for immediate shipment.

Powercrete R65 / Powercrete F1:  Sometimes referred to as Powercrete R65 and sometimes referred to as Powercrete F1 (we call it Powercrete R65/F1) this excellent two part epoxy coating is loved in the field for its fast cure abilities.  Reducing labor costs in the field; Powercrete R65/F1 offers fantastic corrosion prevention properties and will protect your field joints, likely through the life of your pipeline.  Available in 1#, 2# and 4# kits (custom kits also available) we have Powercrete R65/F1 in stock and ready to go for immediate shipment.  

Powercrete R95:  Powercrete R95 is the HIGH BUILD epoxy option.  With the ability to apply a single coat in a 30 mil plus thickness (depending on installer skill of course) Powercrete R95 is an excellent coating that reduces field labor costs, reduces material waste and provides excellent corrosion resistance on pipelines.  Powercrete R95 is available in 2#, 4# or custom kit sizes as needed.  Material on hand and ready to ship.

Powercrete R65/F1 50ml Repair Cartridges:  Powercrete R65/F1 is available in repair cartridge form.  Sold in cases which consist of 25 each of the 50ml cartridges; 50 each of the static mixing tips and 1 each of the dispenser guns; these cartridges can be used to repair minor damage for Powercrete J, Powercrete R65/F1 or Powercrete R95 coatings (DD as well).  

Powercrete R65/F1 400ml Spray Cartridges:  Powercrete R65/F1 in spray form.  With multiple options for different spray tips (straight, right angle, etc) this is a beautiful coating that sprays on incredibly easily.  Generally sold in cases of 10 cartridges, this product is easy to apply.

BBS Bundled Bumper System:  When pulling multiple pipelines through a single bore hole in a bundle, it is important to do two things:  first you want to make sure there is no pipeline coating damage caused by those multiple lines colliding with one another.  Second, you want to make sure that when those lines reach their resting place (when the pull through is completed) you have space between the lines so that your CP can properly protect those lines.  That is where our BBS comes in.   

DIRAX:  The premier heat shrinkable sleeve coating solution for field joints on pipelines that will be involved with road bores and directional drills.  Utilizing a two part epoxy coating as the primary corrosion barrier and then adding in a single component (multi layer) heat shrinkable sleeve with a reinforced backing to make it incredibly strong offers unmatched physical coating characteristics to go along with the excellent corrosion prevention of an epoxy.  Add in a leading edge strip for even more protection on the front end of the line; and you've got yourself an excellent coating that will protect your field joint through the life of the line.

WPCT:  A wrap around shrink sleeve designed for use on standard 'drop in the ditch' application.  Utilizing a butyl mastic sealant, WPCT is rated for use on lines operating at up to 140F.  An excellent and economical solution to coat your field joints.  Available in 11", 17", 24" and 34" widths; WPCT is simple to install and offers excellent field joint coating protection.

WPC100M:  A butyl mastic wrap around shrink sleeve designed to be used on higher temp lines (176F onshore; 212F offshore); WPC100M is a very good coating.   

HTLP60:  In many parts of the world; three layer PE coatings are the factory applied coating of choice.  HTLP60 recreates that three layer coating on the field joints to give a homogenous pipeline coating.  Utilizing a two part epoxy as the primary corrosion barrier and then shrinking a PE sleeve with a hot melt adhesive over that wet epoxy to give it significant physical protection; HTLP60 is a great coating system for non-directional drilling applications.  

Caseal / Casing Seal:  A high shrink, highly reinforced backing helps Caseal to seal up the anulus between your casing pipe and your carrier pipe.  With fantastic penetration resistance; Casing seal prevents water ingress into your casing pipe which extends the life of the pipe significantly.  

FlangeSeal:  Likewise, Flange Seal is a high expansion, heat shrinkable material designed to encapsulate your flange; seal down to the adjacent pipe AND be re-enterable at a later date (by cutting/destroying the Flangeseal). 

WPC120:  High temp wrap around shrink sleeve designed to be used on pipelines operating at up to 248F.

TPS:   A slip on or tubular shrink sleeve.  Very similar to WPCT, TPS is supplied as a tube that must be slipped onto the pipe before the weld is made.  

Waterwrap WAB (weld after backfill):  A product specifically designed to be used on large Water pipe where the sleeve is often welded after this sleeve has already been installed.  

WCSM:  A heat shrinkable tube designed to seal up a splice on a low voltage cable connection (1000 volts). 

Repairing Powercrete Coatings

 How to Repair Powercrete Coatings

    This document is designed to offer a procedure how how to make repairs to Powercrete field joint coatings.  If you are instead looking for information detailing how to make a repair to Powercrete-DD, I would advise you to contact the pipe coater who applied the DD.  That will be your best source.

    When evaluating coating repair options for Powercrete field joint coatings (which may be Powercrete J, Powercrete R65/F1 or Powercrete R95), the starting point is always:  "how much damage is there?"

     In this specific article we are recommending that Powercrete R65/F1 50ml cartridges, Powercrete R95 50ml cartridges or hand applied kits of Powercrete J 2#, Powercrete R65/F1 1# or Powercrete R95 2# kits be used.  Powercrete products are the best choice for repairing Powercrete coatings.  

Detail Conditions of Coating Damage

#1:  Defects 2.5" in diameter and less (including a pin hole)

#2:  Defects larger than 2.5" in diameter

To Repair Damage Less than 2.5" OD (#1)

     For repairing Powercrete Coatings (Powercrete J, Powercrete R65/F1 or Powercrete R95) that are minor, use the following procedure:  Clean any bare metal showing with a wire brush to obtain a clean metal surface.  DO NOT REMOVE THE SURFACE PROFILE.  For adjacent (undamaged) Powercrete, use light sandpaper (60-80 grit) to clean the epoxy surface.  Then wipe the surface clean with solvent to remove dust, dirt, grit, sandpaper residue, etc.  Apply the Powercrete J, Powercrete R65/F1 or Powercrete R95 repair material (talk with JSI customer service to determine most efficient size for your needs) to coat the damage area and adjacent not-damaged area by at least 1" in every direction.  Use a trowel or brush to spread the applied Powercrete repair material over the previously prepared surface.  Insure the Powercrete coating is smooth and the coating thickness is equal to the applied coating thickness outside of this impacted area.  Allow sufficient time for the repair area to cure and then evaluate that coating just as you evaluate the field joint coating area.  Allow sufficient cure time and then follow the procedure set forth by the end user in their specification (in terms of potential hardness testing, holiday testing, etc).  If holiday testing, 125 volts per mil is appropriate.  If necessary, record the defect and repair procedure in the construction journal. 

To Repair Damage Greater than 2.5" OD (#2)

     First thing to do in cases of larger damaged areas:  contractor must determine from the end user coating and construction specification if defects in the FJC of this size are allowed to be repaired, or if the coating must be removed and re applied.  If the end user specification allows the Powercrete product to be repaired, use a one or two pound kit to perform the repair using the same installation steps as listed above under the #1 category.  

Powercrete Installation Procedure

General Powercrete Installation Procedure

     Here is a very general guideline of the things we cover when training crews; or training trainers with regard to field applying Powercrete J, Powercrete R65/F1 or Powercrete R95 as a hand applied ARO or field joint coating. 

1. Preheat the pipe to 120 to 125 F prior to blasting
2. Blast the pipe with suggested grit size
3. Verify that proper anchor pattern has been achieved
4. Re-preheat if necessary to bring pipe surface up above the dew point (or higher if you are wanting to cure faster)
5. Make sure steel and adjacent coating are free of oil, dirt, dust, etc
6. Mix the Powercrete - normally pouring the B into the A
7. Using either a drill or doing it manually, mix the epoxy thoroughly without introducing air into the mixture
8. Mix epoxy until it begins to have a glossy look (typically 3-5 minutes by hand).
9. Pour a bit of the mixed epoxy back into the B container and coat the inside in order to use up all hazardous material in the B container.
10. Pot life will vary significantly based on ambient weather conditions.  The hotter it is, the quicker things cure.  Generally speaking you might have:
1. ~18 minutes for Powercrete J
2. ~8 minutes for Powercrete R65/F1
3. ~15 minutes for Powercrete R95
11. Apply 1st thin coat and let that coat sit until it is tacky
12. Apply next coat, beginning to build coating thickness as needed
13. Monitor the pipe for potential drips until the epoxy has begun to gel and get tacky.

Powercrete J and R95 to Coat Lengths of Pipe

Coating Long Lengths of Pipe with Powercrete J andPowercrete R95

R95 being used to add coating thickness to a line.

Powercrete J testing, training and evaluation 

Powercrete R95 Cure Chart

Powercrete R95 Cure Times

     It is quite a common question: how quickly does the R95 high build epoxy cure?  There are many factors that will determine exact cure times; including ambient temperatures; temperature of the pipe; etc.  Speaking in generic terms, see the below cure information for Powercrete R95 which lists temperature (can be ambient temperature or temperature of the substrate), gel time, re-application time frame, dry time and time to achieve shore D hardness of 75. 

Powercrete R95 Cure Rate @ 150F

Gel Time: 7 minutes

Re-Application Time:  5-10 minutes

Dry Time:  12 minutes

75 Shore D Hardness:  16 minutes 

Powercrete R95 Cure Rate @ 140F

Gel Time: 10 minutes

Re-Application Time:  8-10 minutes

Dry Time:  13 minutes

75 Shore D Hardness:  21 minutes 

Powercrete R95 Cure Rate @ 130F

Gel Time: 11 minutes

Re-Application Time:  9-14 minutes

Dry Time:  18 minutes

75 Shore D Hardness:  32 minutes

Powercrete R95 Cure Rate @ 120F

Gel Time:  14 minutes

Re-Application Time:  12-20 minutes

Dry Time:  29 minutes

75 Shore D Hardness:  37 minutes

Powercrete R95 Cure Rate @ 110F

Gel Time: 19 minutes

Re-Application Time:  16-22 minutes

Dry Time:  31 minutes

75 Shore D Hardness:  75 minutes

Powercrete R95 Cure Rate @ 100F

Gel Time: 23 minutes

Re-Application Time:  20-32 minutes

Dry Time:  40 minutes

75 Shore D Hardness: 90 minutes

Powercrete R95 Cure Rate @ 90F

Gel Time: 26 minutes

Re-Application Time:  22-40 minutes

Dry Time:  60 minutes

75 Shore D Hardness:  135 minutes

Powercrete R95 Cure Rate @ 80F

Gel Time:  37 minutes

Re-Application Time:  32-50 minutes

Dry Time:  95 minutes

75 Shore D Hardness:  330 minutes

Powercrete R95 Cure Rate @ 70F

Gel Time: 57 minutes

Re-Application Time:  52-75 minutes

Dry Time:  140 minutes

75 Shore D Hardness:  540 minutes

Powercrete R95 Cure Rate @ 65F

Gel Time:  60 minutes

Re-Application Time:  55-90 minutes

Dry Time:  150 minutes

75 Shore D Hardness:  600 minutes

Powercrete R95 Cure Rate @ 60F

Gel Time: 80 minutes

Re-Application Time:  75-120 minutes

Dry Time:  180 minutes

75 Shore D Hardness:  5-6 days

Powercrete Repairs

Repairing Powercrete Coatings

     Repairing Powercrete products is a fairly simple proposition; not altogether different than the process of installing it in the first place.  In this case, I'm talking about repairing Powercrete J, Powercrete R65/F1 and Powercrete R95 products; though some of this would also apply to a Powercrete DD repair.

     In addition, there are cases where a Powercrete J (or R65 / F1 / R95) might be installed, but it it latter discovered that the required coating thickness was not reached (in one or more places) and an additional layer is needed in order to meet the spec.

     So in all of those cases, we must start over.  We must create an anchor pattern on top of the previously installed Powercrete product (J / R65 / F1 / R95).  That anchor pattern can be achieved using a brush blast - or it can be achieved using 60 or 80 grit sandpaper.  Then the pipe can be lightly preheated and more epoxy applied.

     We would want that anchor pattern to on every bit of surface area where the Powercrete will be applied.

     In terms of what Powercrete product could be used there are a few options:

- Powercrete R65/F1 is available in 50ml cartridges specifically designed for minor repairs.  A case of R65/F1 50ml cartridges contains 25 cartridges, 50 static mixing tips and 1 dispenser gun. 

- Powercrete R95 50ml cartridges are also available.  These are sold in cases of 12 cartridges, 24 static mixing tips and 1 dispenser gun

- Powercrete R65/F1 1# Kits are the perfect size for making repairs.  Just like a 2# or 4# kit; but smaller. 

- Beyond all of that; we see folks use Powercrete J in 2# kits (or Powercrete R65/F1 and R95) in 2# kits used as repairs.  It all depends on what the spec you are working from requires. 

All of the above items are in stock and ready to ship anytime. 

Powercrete R95 Kits

Powercrete R95 Kits

A full pallet of Powercrete R95 2# Kits wrapped and strapped

     Joint Specialists is now kitting and stocking Powercrete R95 kits in both 2 pound and 4 pound.  These are sold as Powercrete R95 2# Kits and Powercrete R95 4# Kits.  We are able to offer some other sizes if necessary. 

    Available in any quantity of 8; a full pallet of either Powercrete R95 2# or Powercrete R95 4# would contain 192 kits (though we do not require full pallet sales). 

A few boxes of R95 4# Kits - "B" on top; "A" on bottom

      Powercrete R95 is a high build, solvent free, novolac epoxy coating.  It can be used for extra protection on top of FBE mainline coatings or as a direct to metal corrosion prevention coating.  R95 has excellent chemical resistance and can be used on pipelines operating at up to 95C (203F).  Powercrete R95 can a applied in up to 40 mils in one pass.