Question 1

What makes the Ocal-Blue "Triple Threat" protection system unique compared to standard conduit?

Accepted Answer

The system utilizes a three-layer defense strategy to prevent corrosion. It begins with a raw steel shell that is threaded before being hot-dip galvanized, ensuring zinc penetrates the threads rather than leaving them exposed. The second layer is a 2-mil interior and exterior blue urethane coating that protects the steel even if the outer jacket is damaged. Finally, the conduit is encased in 40 mils of PVC with overlapping sleeves at the fittings to create a vapor-tight and moisture-tight seal.

Question 2

Why is the order of threading and galvanizing important for corrosion protection?

Accepted Answer

Most conduit systems are "weakest at the links" because threads are often cut after the galvanizing process, leaving raw steel exposed at every connection point. Ocal threads the raw steel first and then performs hot-dip galvanizing, which allows the molten zinc bath to penetrate both the internal and external surfaces of the threads. This ensures that the most vulnerable part of the conduit run is fully protected from the elements.

Question 3

What specific tools and techniques are required for a successful Ocal installation?

Accepted Answer

Standard tools can shred the 40-mil PVC coating, so installers must use specialized equipment. This includes J-wrenches with aluminum jaws and vise adapters to prevent marring the surface. When using a chain vise, installers should create "shells" from a larger piece of rigid conduit to act as a buffer. Additionally, because the PVC increases the outside diameter, special die heads are required for threading, and the PVC should be scored lengthwise before threading to prevent clogging the die teeth.

Question 4

How can a contractor extend the standard product warranty for their customer?

Accepted Answer

While the standard warranty is two years, it can be extended to five years if the system is installed by a certified professional. ABB offers free, two-hour on-site "Installation Certification Training" for contractors. This training ensures that the installers are using the correct tools and techniques—such as applying Kopr-Shield joint compound to field-cut threads—to maintain the integrity of the corrosion protection system.

Question 5

Which industries are the primary targets for PVC-coated conduit systems?

Accepted Answer

Ocal is designed for the harshest environments where chemical exposure or high moisture is a constant threat. Key industries include wastewater treatment plants, chemical processing facilities, and food and beverage plants that require intense high-pressure washdowns. It is also highly recommended for marine facilities dealing with salt air, oil and gas production sites, and specialized space or defense infrastructure.

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