choosing the right prepainted metal product

8/10/2019 Choosing the Right Prepainted Metal Product

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Choosing the RightPrepainted Metal Product

3 - July 2010

T E C H N I C A L P A P E R


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Contents

An Introduction to Prepainted Metal

Prepainted Metal as a System

What is Paint?

What to Expect from Prepainted MetalPolyesters

Polyurethanes

PVDF

Other Paint Types

Film Coatings

Plastisols

Powder Coatings

Substrate

Which Prepainted Metal to Use

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and chemical conversion process andusually 2, but up to 4 different paintcoatings. The coil coating processallows different coatings to be used onthe two sides of the metal strip, so thepossibilities are endless.

Each producer of prepainted metal

offers their own, sometimes branded,selection of prepainted metal products.It is beyond the scope of ecca tocompare all of these products, butthis ecca Technical Paper attempts toprovide a guide to the main producttypes, together with their main uses,advantages and disadvantages.

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An Introduction to Prepainted Metal

Prepainted Metal as a System

Prepainted metal is a high qualityproduct manufactured under strictquality control in the coil coatingprocess. The main substrates forprepainted metal are steel andaluminium strip and these are usuallycoated with a liquid paint by roller-coating, although sometimes a pre-formed lm is laminated to the surfaceand occasionally a powder-paint isapplied in coil coating.

A prepainted metal product is asynergistic combination of the metalsubstrate, any metallic coating whichmay be used, an ef cient cleaning

In terms of the quality of prepaintedmetal, two main factors set this apartfrom traditional paint coatings onmetal:

The uniformity of cleaning, pre-treatment and coating afforded by thehighly controlled coil coating process;

The synergistic nature of the differentlayers that make up a prepainted metalproduct and which are well thought-outto work together.

A prepainted metal product is acombination of several layers, asdepicted in Figure 1 .

Figure 1. The make-up of a typical prepainted metal product


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It is the combination of these layerswhich provides the nal propertiesof the prepainted metal product, butsome show more variation than others.Prepainted metal products are generallyreferred to by their topcoat and whilethe focus of this paper is mainly on thevarieties of topcoat, it is important toremember that the other layers willalso play a part.

The choice of metal substrate and, toa lesser extent, any metallic coating,is generally one for the customer, butusually the pre-treatment and primer

Images courtesy of Metalcolor

will be selected by the coil coater tobe the most appropriate for a givencombination of topcoat and substrate.Very often, the topcoat is only speci edon one side, with the back-side havinga simple, low-cost topcoat.

However, the back-side topcoat can

also be selected, depending on therequirements in the end use, to giveimproved appearance, improvedperformance, additional functionality orreduced cost.

Thickness of coatings is usually quotedfor the combination of top-coat andprimer. In the majority of cases, theprimer is a thin layer, of the orderof 4 m, the majority of the coatingbeing the top-coat. However, there arecases where a much thicker primer

can be used, such as the high-buildpolyurethanes, where the primer canbe up to half of the overall thickness.For multi-coat systems, such as 3-or 4-coat PVDF, the total thicknessincluding primer and 2 or 3 top-coatsis usually quoted, the thickness of eachlayer being required for its individualfunction in the total system.

There are three main categories of top-coat:

Liquid paint

Film

Powder paint

Over 90% of prepainted metal usesliquid paint, so a fuller description isgiven here of what makes up a liquidpaint and what differentiates one paintfrom another. Films and Powder paintsare covered later in this paper.


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What is Paint?

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Liquid paints account for morethan 90% of the coatings used forprepainted metal. Liquid paints aremade up of four main constituents:

Pigments Binders

Solvents

Additives

The solvent is used as a deliverymechanism, allowing the paint toow-out and give a smooth wet lmbefore drying and curing. They are notincorporated into the nished product.The function of the nished product isa combination of the binder, pigmentsand additives, but coatings are usuallycategorised by the type of binder used.

The binder is a polymeric materialwhich gives structure to the paint. Themain types of polymers used for coilcoating paints are:

Polyester

Polyurethane

Polyvinylidene uoride (PVdF)

PVC (plastisol)

Categorising coil coatings into thesefour main categories presents a muchsimpli ed view, since there are manyvariations between coatings withineach category and indeed somecoating types which fall outside ofthese categories. These variationsare discussed in more detail in thisTechnical Paper, where each of these

categories of coating are reviewed.

Pigments used in coil coatings aregenerally inorganic and they provideboth colour and certain physical

properties such as corrosion protection.Meanwhile, various additives areincluded in the paint formulation tomodify aspects such as paint ow,speed of curing, UV absorption andgloss.

Image courtesy of Euramax

Image courtesy of Beckers


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What to Expect from Prepainted Metal

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Before introducing the variouscoating types available for prepaintedmetal and their various bene ts,it is important to understand therequirements which can be placed upondifferent prepainted metal products andwhich can be best served by differentproducts.

The requirements for a prepaintedmetal product are de ned by the enduse to which it will be put, so beforechoosing a product it is worthwhile toanswer the following questions:

How severe will the forming operationbe?

How long do I expect the product tolast?

Will the product be exposed to

outdoor weathering, eg sun, rain andpollutants?

Will the product be susceptible toscratching, either in manufacture or inthe end use?

Are there any special requirementsfor the product, eg temperature orchemical resistance?

What visual appearance do I want, egsmooth or textured; gloss or matt?

The answers to these questions willhelp in de ning the performance thatis required and of course this is then tobe balanced against cost.

The basis of prepainted metal is thatthe nished coating is present beforeforming the nal article. For thisreason, coatings require a good degreeof exibility and scratch resistance toensure that the coating on the nishedarticle is as expected. There has

traditionally been a trade-off betweenexibility and hardness of a coating.This is still true, but in some cases,modern prepainted metal can give avery exible coating, capable of severeforming, while retaining a good degreeof hardness and resistance to marking.

In terms of in-life performance, thedemands on prepainted metal aremuch the same as on any other metalcoating to look good and to continueto look good for the life of the product,while protecting the metal substrate.In some cases, this means a resistanceto fading in UV light or to assist inprotecting he metal substrate fromcorrosion, while in others, it might beabout resistance to chemical attack orhigh temperatures.

All of these properties are availablein prepainted metal products, but ofcourse, improved performance willcome at a cost, so it is important tospecify a product which meets therequirements which are importantin a given application without over-specifying an expensive product.


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Polyester

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Typical properties

The term polyester describes a familyof chemicals which can be used asthe basis for paints as well as manyother plastics. Polyester bindersare by far the most popular for coilcoating. However, the speci c natureof a polyester binder can provide verydifferent functionalities to the nalpaint coating and a polyester usedfor cladding products would require adifferent speci cation to one designedfor consumer products.

Polyesters are the workhorsecoatings of prepainted metal. At theirmost basic, polyesters can offer aneconomical product with reasonablygood performance across the board.A standard polyester product wouldhave a 2025 m coating with limitedexibility and moderate durability whenexposed as the top-weathering surface.Modi cations can be made which canimprove the exibility,

Polyesters can be made from a widevariety of acids and alcohols to producea large choice of resins with differentproperties. To produce a polyestercoating, the polyester resin is cross-linked with a melamine formaldehyderesin. The ratio of solid resin to cross-linker is usually between 70:30 and90:10 with higher melamine contentsgiving a harder surface, but poorerexibility.

although there is usually a penalty inhardness.

Basic polyesters have only moderateresistance to the effects of UV light

and provide a basic barrier coat to helpprevent corrosion of the substrate.For the basic product, resistance tochemicals, staining or dirt is moderate,but modi cations are possible whichimprove each of these.

Modifcations

As the most widely used prepaintedmetal product, there are a largenumber of variations of the standardpolyester. Thicker polyester coatingsup to 60 m are used to provide extradurability in some outdoor applications,while thinner polyester coatings areused where cost is important, or toprovide a basic backing coat.

Modi cations in the chemistry of thepolyester binder and in the additivesused can provide virtually any desirableproperty in a polyester coating. Image courtesy of ThyssenKrupp Steel


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Polyesters are used for both internaland exterior products, but the exactspeci cation of each is tailored to theparticular application.

As an exterior product, basic polyestersare used for both wall and roof claddingon buildings, particularly in mild anddry climates. This represents the mosteconomical choice for such buildingapplications, although the durability canbe somewhat limited. Highly durablepolyesters and higher-build systemsare widely used where a greaterdurability is required. Apart from walland roof cladding, polyesters are usedfor most other external applications ofprepainted metal, again subject to theirlimitations in durability.

Polyester coatings are the basis ofmost internal applications of prepaintedmetal. Very often the coatings canbe the same as the basic exteriorpolyesters, but many variations areused. Many indoor applications aresubject to greater scrutiny than exteriorapplications, so high quality aestheticsare important, often coupled with goodformability for forming into speci c

Usesparts and a high degree of scratchresistance. All of these propertiescan be available in polyester coatingswhich are used in highly decorativeapplications such as the front panels ofelectronic appliances and also for morefunctional applications such as ducting.

A sub-class of products often referredto as Highly durable polyestershas emerged recently with improvedformulation making for a signi cantlyimproved durability, particularly inresistance to UV degradation.

Silicone-modi ed polyesters were once

popular and still are in many parts ofthe world, although they have beenlargely superseded in Europe by highlydurable polyesters which give similarbene ts, but without the penalty in

limited exibility and generally at areduced cost.

Polyesters usually present a smoothsurface, but with either the additionof polyamide particles (sometimesreferred to as polyamide-polyester) orwith a structured base layer, textured

surfaces are also available. Apart fromthe obvious aesthetic bene ts, thesetextured products are often highlyscratch resistant.

Image courtesy of ThyssenKrupp Steel


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Polyurethanes

Polyurethane coatings are chemicallysimilar to polyesters with the additionof isocyanates in the formulation.Being chemically similar, polyurethanesexhibit many of the same properties

Compared to polyesters, polyurethanesare capable of producing thickercoatings and so where durability isimportant, high-build polyurethanecoatings are nding increasing use.These thicker versions also offerimproved corrosion resistance to themetal substrate.

Modifying the isocyanate level in thepolyurethane can provide a highlyexible product, while modifying thetype of isocyanate can provide verygood resistance to UV light.

Basic polyurethanes are availablewith a thickness of around 2025 m,but thicker products of 50 m oreven 60 m are commonly produced,often with a high-build primer (up to30 m) which can help to give verygood corrosion resistance for outdoorexposure.

Typical Properties

Modifcations

Polyurethanes are capable of highlevels of exibility which is oftendesirable for prepainted metal and theyalso tend to be a bit more scratch-resistant than polyesters. However,polyurethanes do generally cost morethan basic polyesters.

Particularly with the thicker

polyurethane coatings, polyamidebeads are often incorporated whichprovide a textured surface and a veryhigh level of scratch resistance. Thisis important in some interior productswith high aesthetic demands, but alsoin exterior products where scratchingof building panels, for example duringconstruction, can cause long-termcorrosion problems.

as polyesters, but are capable ofimprovements in some areas. The useof polyurethane coatings for prepaintedmetal has grown recently because ofthese desirable properties.

UsesPolyurethane coatings generally costslightly more than polyesters, so theyare used where the bene ts outweighthe cost differential. The high-buildproducts are widely used in roof andwall cladding because of their improvedcorrosion and UV resistance, coupledwith the scratch-resistant properties ofthe polyamide-modi ed varieties.

The other important property ofpolyurethanes is the improvementin the exibility / scratch-resistancebalance, so for premium interiorproducts such as many domesticappliance applications, they havebecome a much favoured option.


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PvDF is a highly stable resin whichis actually not cured in the paint inthe same way as polyesters, but isfused in the paint layer, a so-calledthermoplastic coating. Unlike mostpolymers, the PvDF resin is not affectedby UV radiation, so it remains verystable for long periods in sunlight.

Polyvinylidene Fluoride (PvDF)

PvDF products tend to have coatingsin the thickness range of 25 m to28 m, although multi-layer systemscan have higher thicknesses up to55 m. Unlike for polyurethanes, high-build PvDF is made up of up to 4 layersof paint rather than the usual 2.

As mentioned above, PvDF is notsusceptible to attack by UV light, sothe resin does not break down onexposure to sunlight, unlike virtually allother polymers. This gives a very highresistance to fading, and chalking anda very good long-term maintenance ofgloss and colour.

There is a drawback to the UVresistance in that the UV light can thentravel through the resin and attackthe primer. As this breaks down, thereis potential for a loss of intercoatadhesion and the PVdF layer candelaminate. For this reason, the choiceof pigmentation for PVdF coatings isvery important since the pigments arerequired to absorb UV light and protectthe primer. Ceramic blue, green andblack pigments should not be used ontheir own because they also permit thepassage of UV. As a result, the colourpalette in PVdF can be limited. Thiscan be overcome in high-build systems

Typical Properties

where either a pigmented base coat ora clear, UV-absorbing top-coat can beused, but the additional coating layerscan add considerably to the cost.

Apart from being resistant to UVlight, the PvDF resin is also highlyresistant to many chemicals and itcan have excellent stain resistance.PvDF coatings tend to be a bit moreexible than basic polyesters, but theirresistance to damage from scratching islimited and they provide no additionalcorrosion protection to the metalsubstrate. They also tend to be morecostly than most other coating systems.


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In Europe, PvDF is almost exclusively

used for external wall cladding andfacades. PvDF attracts a cost premiumover polyester, to which the initialappearance is similar, so it is used

Modifcations

Uses

There are different standards ofPvDF resin available notably 80:20and 70:30, the latter being the mostcommonly used for prepainted metalas it provides the optimum balance ofperformance across a range of factorsand importantly for prepainted metal,the optimum exibility.

As discussed above, multi-layer PvDFproducts are available. In some cases,this is used to ensure UV stability forspeci c colours, but it can also be usedto ensure the richness of particularly

bright colours or a high-gloss nish, orto provide additional robustness to theproduct.

As a premium building product, PvDFis often modi ed to provide additional

functionality. An example of this is anti-dirt coatings where the exterior surfaceof the PvDF product will be modi ed toavoid the retention of dirt. In a similarway, anti-gra ti coatings can be appliedto the outer surface which allow anygraf ti to be easily cleaned away.

where the long-term colour durability

will be appreciated, particularly forcladding and facades on prestigiousbuildings.



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Plastisols

Plastisols are high-build thermoplasticcoatings based on polyvinylchloride(PVC). Plastisol coatings are actuallydispersions of PVC and pigments in aplasticiser which is fused, rather thancured, in the coating process. Oncecooled, the resulting lm is tough andexible. Before fully cooled, a pattern isusually embossed in the thick plastisolcoating. This is very often a leather-grain type pattern, but other patternsare possible.

Plastisols are very different to mostother coil coatings in that they are thicklm coatings, typically 200 m thick,although products from 100 m to300 m can be available. This thick lmis very robust, giving excellent abrasionresistance. The thickness of this lmalso provides an element of corrosionprotection to the metal substrate whichis not possible with thinner coatings.

Traditionally, plastisols have sufferedfrom being very susceptible to colour-fade, chalking and gloss reduction.However, recent developments inplasticisers and stabilisers havemostly eliminated these problems and

plastisols can now compete well oncolour stability.

Although the coating is very thick,the thermoplastic nature means thatforming stresses are very low, soplastisol products tend to be highlyexible with little thinning in formedareas.

The thick plastisol coating gives agood barrier against weathering,but it can be susceptible to chemical

Typical Properties

attack, particularly from solvents.Being thermoplastic, the coating isalso affected by high temperaturesand should not be used at constanttemperatures above 80C. Of course,plastisols tend to also cost slightly morethan basic products too.

The plasticiser type and content affectsthe exibility and often mixtures ofplasticisers are used. Traditionally,phthalate plasticisers were used, butthese have now been mostly eliminatedfrom the coil coating industry in favourof more environmentally friendlyalternatives.


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As mentioned above, there are nowdifferent grades of plastisol available,the more advanced of which havelargely overcome the colour-fadingissues of the past. Some of these

products now come with very longguarantees.

One of the properties of plastisol isthe embossed surface and different

As for PvDF, plastisols tend to be abit more costly than polyesters, sothey are used where their bene ts willbe valued. The additional corrosionprotection provided by the thick coatingis particularly bene cial in roo ngwhere rain-water run-off can promotecorrosion. Plastisols are also favouredfor other building applications because

Modifcations

Uses

their robustness makes damage duringthe construction phase less likely thanfor other thinner coatings.

While the main use for plastisols is in

buildings, they are also sometimesused where abrasion resistance isimportant, for example in the casing ofindustrial equipment.

embossing patterns are available.The typical emboss is a leather-grain,but more subtle random patterns areavailable and some manufacturersare also producing plastisols with a

more regular, dimpled-type emboss.However, for most applications, onceviewed from a distance, the emboss isnot noticeable.


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Other Paint Types

In the preceding pages, we describedthe four main paint types used for coilcoatings. Some manufacturers refer tothem in this way, while others will usebrand names, but for the majority ofapplications, these are the coil coatings

Once popular, acrylics are now seldomused in Europe. The acrylic resincan give good hardness and scratchresistance and can be tailored to givevirtually any colour and gloss level.However, acrylics suffer from a lackof exibility, so in Europe at least,most users have switched to polyestercoatings which offer many of the samebene ts in a more exible coating.Acrylics are still used in some places,

particularly for at applications such assignage.

Although historically important, morerecently, epoxy resins have only beenused for primer paints. Adhesion tothe metal surface and to other top-coat paint systems is very good, butepoxies tend to have limited exibility,so their use in primers is now declining

signi cantly in favour of polyester andpolyurethane-based primer systems.

Acrylic Coatings

PTFE

Epoxy Coatings

For specialist, high-temperatureapplications, particularly bakeware,PTFE coatings can be applied by the coilcoating process. As for plastisols, thesecoatings are fused rather than curedand very high oven temperatures are

required. These coatings give excellentnon-stick properties for bakeware,which can be formed from prepaintedmetal, and recent developments haveimproved their robustness too.

in common use in Europe. However,there are other paint types which mayhave fallen out of favour recently, orare better suited to other global regionsor have speci c niche applications.

Image courtesy of Metalcolor


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Powder Coatings

Powder coatings are usually applied topre-formed parts, but in some cases,they are also applied to at strip metalin coil coating lines. Powder coatingsare made by producing solid paint andpowderising this. The powder, onceapplied to the substrate is heated tofuse together the individual particlesand form a continuous paint lm.

Powder coating is a dry process, usingno solvents, so in principle it could bean environmentally friendly alternativeto wet painting. However, for coilcoating, powder suffers from limitationsin speed and in producing thin paintlms, both of which make this moreexpensive than standard coil coating.However, there are applications wherepowder-coated coil and sheet can bepreferable.

Powder coatings tend to be availablein a wide range of colours and nishesin relatively small batch sizes andswitching between colours is relativelyeasy. This is one of the main reasonswhy some coated coil uses powderpaint. Certain surface textures, suchas an Orange peel type effect arereadily achievable in powder paints, butmuch more dif cult in coil coatings, sofor specialist applications where thistexture is required, powder coated coiland sheet is generally used.

In the long term, it may be thatapplication technology will improve tothe point where powder paint is costcompetitive with standard coil coating,but for now, this is still a niche in thecoil coating industry.

Image courtesy of Novelis


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Laminate Films

In some cases, the surface propertiesrequired from prepainted metal arebest produced off-line on a stand-alonelm, which can be laminated onto themetal strip. Such products are calledlaminated lm products. Typically, anadhesive is applied to the strip usingthe top-coat roller coater and the lm isapplied while this is still hot.

There are 4 main lm types of laminateused: polyvinyl chloride (PVC),polyvinyl uoride, thermoplastic acrylicsand polyethylene terephthalate (PET).Their advantages include high exibilityand suitability for deep drawing, while

PET (polyethylene terephthalate) lmsare typically supplied clear, and arehot-laminated onto the last paint layeron coil coating lines. Products obtainedby this method are referred to asco-laminates, being both painted andlaminated. They meet the technicalrequirements of domestic appliancemanufacturers like high exibility,hardness (scratch resistance), nocracking during processing, chemicalresistance (aggressive environments,detergents, solvents, etc.), anti-

gra tti, foodsafe certi cation and reresistance.

PET lms can also be made available incolours such as seen inside baby food

PET flms (Co-Laminates)

cans or the bottom of aerosol cans.These are different to conventionalco-laminates in that they do not use abase layer of paint to obtain colour butrather have the colour built directly intothe PET layer.

Appliances like refrigerators andfreezers are the most importantindustrial applications for co-laminates.A multitude of colours can be obtainedby modifying the underlying paintcolour. Both smooth or structuredsurface appearances, coloured ortransparent lms are available.

they can also have very high gloss andgood hardness.

Certain lms have a primarily exteriorrole (resistant to rain, sun, heat, etc.)while others are resistant to re, stains,abrasions or aggressive chemicals.These properties make laminated

lm products widely used in electricalappliances, furniture, clean-rooms, coldstores and ship-building.

For speci c appearances, laminatedlms are available with printed patternsor with embossed textures.


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Substrate

Usually the main consideration inchoosing a prepainted metal product isthe nature of the coating. However, theunderlying substrate is a fundamentalpart of the product. The rst andmost obvious distinction is what typeof metal to use. Most prepaintedmetal uses either steel or aluminium,although other metals such as copperor zinc can be available with a coilcoated surface too.

In both steel and aluminium, there arevarious grades available which can giveeither greater strength or improvedformability, as well as variations inresistance to corrosion.

When using steel, most prepaintedmetal also uses a metallic coatingon the steel to improve corrosion

resistance. This is not always thecase and for some applications wherecorrosion resistance is not critical(eg dry indoor applications) the paintcoatings can be applied directly tountreated, cold reduced steel.

The most common metallic coatingfor steel is hot dip galvanising, whichgives a thin zinc layer on the steel.This acts as a sacri cial corrosionprotection layer, corroding slowlyin preference to the steel. Some

variations of the galvanising layer arealso available, mostly using an alloyof zinc and aluminium, usually in theratios 95:5 or 45:55 and sometimes

with some addition of magnesium.These different metallic coatings canimprove corrosion resistance furtherand can be particularly effective whenused together with a paint coating inprepainted metal.

When using aluminium, the exact

alloy can have a signi cant impact onthe corrosion resistance, so it is wiseto take advice on this early in theselection process. In the coil coatingprocess, the steel or aluminium stripis ef ciently cleaned and pre-treatedwhich again helps to improve paintadhesion and corrosion resistance.



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Which Prepainted Metal Product to Use

To summarise, the answer to thequestion of which product to usedepends very much on the combinationof factors which are expected in theend use. Although there are only fourmain coating types, there are so manyvariants within these that virtually anyrequired combination of properties isavailable, at a price.

Some products have very speci c uses,such as PvDF which is used wherecolour fastness is very important, forexample on the facades of prestigiousbuildings, or plastisol which is veryrobust and helps prevent corrosiondamage, particularly in coastalregions. However, even these productsare often put to other uses and theplethora of variations of polyurethaneand in particular polyester makegeneralisations impossible.

The descriptions given here should givea brief guide to what is available andwhat to expect. The exact product touse should be agreed upon betweenspeci er and supplier and will be basedon the requirements of the end productsuch as:

Formability

Durability

Robustness Corrosion protection

Visual appearance

Cost

And any special requirements such aschemical resistance

As discussed, it is important to matchthe coating to the required metalsubstrate, which will dictate factorssuch as formability and corrosionresistance. It is also important tothink about the backing coat. For mostapplications, the reverse side is hiddenand not subject to any signi cant wear,so a simple, thin coating (usually apolyester) can be used. However, thereare cases where the backing coat canbe equally as important as the topcoat and here careful selection can berequired.

Whatever product is chosen, prepaintedmetal has been developed for over40 years by a combination of metalsmanufacturers and paint suppliersworking in harmony to give the bestperforming coated metal productsavailable.

Image courtesy of Beckers


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European Coil Coating Association

Rue du Luxembourg 19-21B-1000 Brussels (Belgium)

Tel.: +32 2 513 60 52Fax: +32 2 511 43 61

E-mail: [email protected]: www.prepaintedmetal.eu

ECCA MISSION STATEMENT

ECCA is dedicated to the promotion of the use of

coil and/or sheet coated metal as the environmen-tally sound, the cost effective and the high qualitymethod of finishing.

ECCA OBJECTIVES

Setting quality performance standards anddeveloping test methods

Promoting the benefits of coi l and/or sheet coatedmetal with par ticular emphasis on environmental,

cost and quality benefits.

Stimulating product, process, application andmarket development

Increasing the awareness of coil and/or sheet-coated metal through professional marketing and

by organising educational training programmes fornon-users

Creating an industry network and forum for thedevelopment and exchange of ideas

Representation of the Industry in its contacts withPublic Officials and Public Authorities

Providing liaison with other Trade Associations andProfessional Bodies.

choosing the right prepainted metal product

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