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updated on March 18, 2019

Reduction of life cycle cost (LCC) through the development of a high-permeability, super durability colored sealer for spray coating film

D&D Corporation

Project name Development of a one-pack type, solvent-free, high performance, inorganic sealer, and development of the technology for other uses
Target downstream fields Industrial equipment、Other(Industrial equipments, other (bridges / steel-framed structures))
Response to the needs of downstream companies High function (improved precision / performance)
High durability (improved heat resistance / corrosion resistance / abrasion resistance)
Mass reduction (size / weight reduction)
Optimization (improved productivity / work efficiency)
Environmental considerations (removal and detoxification of impurities / waste reduction / CO2 reduction)
Cost reduction (running cost reduction / loss elimination / labor saving)
Short delivery time (lead time reduction / process simplification)
Aesthetic value (design-related improvements)
Specific numerical values relating to the above needs 29% reduction in construction costs through the simplification of sealing / coating
Number of days required for construction time reduced from 4 to 1, 50% reduction in 50-year LCC
Project implementation period 2010
Commercialization status Commercialization completed (Already has sales results)
Target materials Spray coating materials such as stainless steel, steel, aluminum, zinc and alloys

Project details

Project background
D&D developed a solvent-free inorganic sealer for spray coating films. With its durability, heat resistance and insulation properties, the product is being sold as a sealer for advanced spray coating films applications for semi-conductors, paper-making machines and other industrial machines. However, the company aimed to create a higher-grade, lower-priced spray coating sealer for bridges and steel-framed structures, by substantially improving the permeability with regard to spray coatings and the concealability with regard to coatings. This resulted in a long life span for the company's capital stock and reduced LCC, and through the use of this highly permeable material in advanced spray coating films applications also contributed to the expansion of state-of-the-art businesses.
Points of R&D
Spray coating technology can be largely categorized into anti-corrosion spray coating for steel structures and spray coating for adding properties like wear resistance and electric insulation in various industrial fields. However, in either case, the sprayed coating films will have many pores, voids, and cracks, and to improve the physical and chemical properties of the coating,films a sealing treatment, through which a sealer will permeate and cover the pores, is applied. Substances consisting of organic coating materials diluted with solvents had come to be used for these sealer, but we aimed to improve performance further by eliminating the disadvantages of these diluted organic sealer and creating a one-pack type, solvent-free, inorganic sealer that (1) would not require solvents, (2) would completely seal the pores in a sprayed coating film, (3) would enable simultaneous application of sealer and coating, and (4) would not be susceptible to ultraviolet deterioration.
Specific R&D results
1. Reduction of work periods as a result of simultaneous application of sealer and coating: from 4 days to 1 day
2. Reduction in construction costs: 29%
3. Prolonged period of durability for maintenance of appearance as a result of inorganic coating: lengthened from 20 years to 40+ years
4. 50-year LCC reduction: 50%
Anticipated fields / products etc. to which this technology may be applied in the future
Anti-corrosion spray coating for steel structures, spray coating for industrial machines and components

Work toward commercialization

Activities related to intellectual property and publicity A patent for the product was applied for and registered before the project started
Promotional activities: (1) Disclosure of the technology on our website; (2) Publication of a technical paper in a spray coating magazine; (3) Sales promotions conducted by our distributors.
Future outlook Our objectives of achieving high permeability and reduced work periods have been fulfilled, and we are continuing to evaluate durability and thinning of sealed coating (which will further reduce construction costs) achieved through improvements to the coating's concealing properties.

System of R&D

Organization managing the project Mie Industry and Enterprise Support Center
Certified business operators D&D Corporation
Institutions conducting the research D&D Corporation, Joining with Welding Research Institute Osaka University; Department of Materials Science and Engineering, National Institute of Technology, Suzuka College

Promotion comments

D&D aspires to help make a sustainable society a reality through the development of inorganic sealer and coating materials that can reduce the maintenance and life cycle costs of steel, concrete and wooden structures, which form society's foundation. Although most of the products for each respective field have been developed, we are continuing our efforts to develop products with improved performance that can meet an ever wider range of needs.

Corporate information

Company name D&D Corporation
(Corporate Number:2190001017799)
Address 7870-21 Sakura-cho, Yokkaichi-shi, Mie-ken 512-1211, JAPAN
Phone number 059-329-8680
Number of employees 7(male  6,female  1)
Capital 199.15 million yen
Business category Chemical industry
Business content Development, manufacture and sale of inorganic sealer Applications: sealing of sprayed coating film, coatings, concrete protection, wood protection, protection for stones, tiles etc.
URL http://www.ddcorp.co.jp
Production base area Domestic location:Domestic location: Outsourced (Osaka, Mie)
Overseas production response Not available
Main clients Sale to end customers is via distributors End customers: Expressway companies (Hanshin Expressway, Tokyo Metropolitan, NEXCO), local municipal authorities, Mitsubishi Heavy Industries, Ltd., Tocalo Co., Ltd., Hitachi Zosen Corporation, and other private companies
Department handling inquiries for this project Shigekazu Mizukoshi, CEO

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