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Sustainable innovation in coil coating
Dublin|24 October 2013
1DP Associates ‐ Novelis
Dr. Ir. Chantal BrettonEuropean Coil Coating Association
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ARCHITECT: Thomson AdsettPrepainted aluminium (3A Composites)
PORT OF BRISBANE ‐ AUSTRALIA
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ARCHITECT: MacGabhann ArchitectsPrepainted Steel (Tata Steel)
CARTON LEVERT HOUSE ‐ IRELAND
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ARCHITECT: Juri SerjoginPrepainted Aluminium (Novelis)
SPORTS CENTRE – ODESSA ‐ UKRAINE
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ARCHITECT: Sergio BaraganoPrepainted Steel (ArcelorMittal)
AVILES WAREHOUSE ‐ SPAIN
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ARCHITECT: BenoyPrepainted Aluminium (Euramax)
FERRARI WORLD – ABU DHABI
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ARCHITECT: Chetwood ArchitectsPrepainted Steel (Tata Steel)
CHATTERLEY VALLEY BLUE PLANET DISTRIBUTION CENTRE ‐ UK
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NAILLOUX ‐ FRANCE
ARCHITECT: Axel Letellier
Prepainted Aluminium (Alcoa architectural products)
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ARCHITECT: Herman HertzbergerPrepainted Steel (TataSteel)
WATERVILLA MIDDELBURG ‐ NETHERLANDS
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ARCHITECT: South China University of TechnologyInstitute of Architectural Design
Prepainted Aluminium (Hunter Douglas)
SHANGAI EXPO CHINA PAVILION
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BRIGHTON ‐ UK
ARCHITECT: RH PartnershipPrepainted Steel (Tata Steel)
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I. ECCA and coil coating
II. The markets for coil coating
III. Sustainable innovation
Content
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What is Coil coating ?
• ‘A method in which an organic coating material is applied on rolled metal strip in a continuous process.This process includes cleaning if necessary and chemical pre‐treatment of the metal surface and either one side or two side, single or multiple application of (liquid) paints or coating powders which are subsequently cured or laminated with plastic films.’
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Coil Coating processThe process consists of the following operations :• Cleaning (alkaline degreasing)• Surface treatment (role: improve adhesion between metal and paint, and corrosion
resistance)• Primer application (role: bind the topcoat to the substrate, and corrosion resistance)• First curing oven• Topcoat application (role: aesthetic and protective)• Second curing oven• Protective film (if any)• On‐line inspections
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Coil Coating isthe best technology available for applyingpaint to metal…
Only uses thin paint films (using less paint!)
Easier to paint a flat surface than a fabricated one
Close control over the coating operation results in a high quality, reproducible and reliable finish
Allows forming 15
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Coil Coating process isenvironmental friendly…Very well and strictly controlled way to dry and cure the paint (in seconds) dramatically cut emissions of harmful VOCs
Usage of chemicals, water and energy are minimised
Waste generation and disposal are minimised
CMR substances(pre‐treatments and paints) are substituted
Continuous process improvements 16
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Prepainted metalhas major advantages …
• Longevity, corrosion protection and long‐term aesthetics
• High constant quality product
• Maintenance or replacement is reduced or even eliminated
• 100 % recyclable at end‐of‐life 17
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European Coil Coating AssociationECCA is the voice of the Coil Coating industry in Europe, representing 130 companies active in coil coating and the
major suppliers to the industry.
ECCA is dedicated to the promotion of the use of coil and/or sheet coated metal as the environmentally
sound, the cost effective and the high quality method of finishing.
• Founded in 1967• Headquarters located in Brussels• Association of corporate companies (≠ federation of national associations)
• 1 320 million m² and 194 kt paint (*)• 83% Steel / 17% Aluminium(*)
(*) 2012 ECCA statistics
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• Increasing the awareness of prepainted metal through targeted marketing programmes
• Promoting the benefits of prepainted metal through the provision of innovative solutions and with particular emphasis on environmental, cost, quality and design benefits
• Stimulating market, application, product and process development
• Setting quality performance standards and developing test methods
• Creating an industry network and forum for the development and exchange of ideas
• Representation of the Industry in its contacts with Public Officials, Public Authorities, other Trade Associations and Professional Bodies.
MISSION Objectives
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38European Coil Coaters (Alcoa, ArcelorMittal, Hydro Aluminium, Novelis, Rautaruukki, Salzgitter, TataSteel, ThyssenKrupp, US Steel …)
3 European Stockists
15 European Paint Suppliers (Akzo Nobel, Beckers,BASF, PPG, Valspar…)
44 Other European Ordinary Members (Arkema, Bayer, Chemetall, Henkel, Solvay…)
3 European Extraordinary Members 27 Non-European members 130
ECCA Membership
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ECCA major activities
Communication, Promotion, Education
Statistics
Standards and Tests methods development
Environmental Benchmarking
Legislation monitoring
Technical projects
Conferences (spring conference opened to customers)
New project: Quality Label21
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ECCA major activities
Communication, Promotion, EducationStatistics
Standards and Tests methods development
Environmental Benchmarking
Legislation monitoring
Technical projects
Conferences (spring conference opened to customers)
New project: Quality Label22
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Creative Buildingwww.creativebuilding.eu
• Collection of high quality buildings made of prepainted metal
• Primarily dedicated to Architects
• Currently more than 40 buildings are detailed and illustrated by pictures and drawings
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The ECCA collection ‐magazine
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Target audience : architects and major European architecture schools
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Creative Roofingwww.creativeroofing.eu
• For roofing applications
• Includes :– a roof simulator where the visitor can choose its roof type, colour and aspect
– the 7 benefits to end‐users in terms of environmental care, cost effectiveness, thermal insulation, performances...
– an architect testimony
– case studies26
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ECCA Academywww.prepaintedmetalacademy.eu
• Free e‐learning platform
• Comprehensive information on Coil Coating process, markets(statistics), product technology,
• When completing the 9 modules the visitor is awarded with an ECCA Academy Degree
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ECCA major activities
Communication, Promotion, Education
Statistics
Standards and Tests methods development
Environmental Benchmarking
Legislation monitoring
Technical projectsConferences (spring conference opened to customers)
New project: Quality Label28
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Colour assessment of prepainted metal ECCA recommendations (*)
Why is colour management important?
Colour: basic principles
Colour characterisation
Colour management
Colour difference tolerances
Colour matching and specification
(*) available on ECCA website
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To ensure tonal consistency, all
material should come from the same
production batch
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RAL 1015Light ivory
ΔL=-5 ΔL=+5
Δa=+5Δb=+5
Δa=-5 Δb=-5
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Colour category definition
• Colour classification by category is obtained from the colourparameters L*, a*, b*, C*
‐ Category 1: light colours
‐ Category 2: medium colours
‐ Category 3: dark colours
‐ Category 4: sharp/saturated colours
‐ Category 5: metallized colours
Colour management
NOTE! Colours that do not fall into any category are classified by the paint supplier.
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Colour tolerance recommendations
General tolerances to be applied using 45/0°, 0°/45 and D/8°geometries with spectro equipment
Note! The supplier has the final responsibility of defining the colour category of his products. This applies particularly for special, demanding colours and cases where the colour is close to a limit between two categories, or where a colour shade falls out of any category
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• Metallized colours: Interaction light‐material
Colour tolerance recommendations
• ΔE* measurement can be disturbed by interaction between the incoming light and the surface of the metallic flake. Visual control remains important.
• Specular reflection on metallic fillers: mirror effect, variable effect on the reading depending on the orientation of the angle
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ECCA major activities
Communication, Promotion, Education
Statistics
Standards and Tests methods development
Environmental Benchmarking
Legislation monitoring
Technical projects
Conferences (spring conference opened to customers)
New project: Quality Label35
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Increasing amount of materials on the market not fulfilling the requirements of the national and European quality and sustainability standards
Increasing competition on price at the cost of quality and sustainability
All actors on the market are not constrained by REACH
No visible way to prescribe quality and sustainability
Competitive and well‐known quality marks on the market, e.g. Qualicoat
WHY a quality and sustainability label?
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Philosophy behind ECCA Premium®Goals and objectives
Make “Quality & Sustainability” top criteria for product selection by decision makers along the construction chain
Fight against low quality materials: promote sustainability and quality upgrade of products and ensure a level playing field and fair competition
• Avoid deterioration of coil coating image by promoting sustainable and high quality product & processes
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ECCA Premium® proposalScope
A quality and sustainability label, which ensures that the processes of manufacturing are done in accordance
to a well‐defined standard
Application for the label by written statement
Granting the label based on independent inspections and test procedures
Technical and sustainability criteria
Product and manufacturer specific requirements
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Product quality Manufacturing quality
Product with minimum requested performance level according to EN10169 (steel) and EN1396 (Al)• Substrate type (aluminium only)• Metallic coating thickness (steel only)• Organic coating thickness & tolerances• Colour consistency and gloss tolerances• Adhesion and bendability• Corrosion, UV, and fire resistance
Manufacturer adopts duly accredited quality (ISO9001), environmental (14001 or EMAS) management systems
Manufacturer is able to ensure regular quality control for the following:• Substrate type (aluminium only)• Metallic coating thickness (steel only)• Organic coating thickness & tolerances• Colour consistency and gloss tolerances• Adhesion and bendability
Product sustainability Manufacturing Sustainability
Product does not intentionally contain any Substances of Very High Concern that are included in the Annex XIV of REACH
Manufacturer adopts a duly accredited safety management system (OHSAS18001 or similar)
Manufacturer is committed to follow the European legislation and limits set for resources consumption (energy and water), VOC emissions and production of wastes
ECCA Premium® proposalContents – technical and sustainability requirements
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I. ECCA and coil coating
II. The markets for coil coating
III. Sustainable innovation
Content
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European Prepainted Metal market in 2012 (ECCA statistics)
Sales of prepainted metal in Europe in 2012Total: 1 292 mio m² (5 317 Kt): 84% steel / 16% aluminium )
76%
6%
5%
2%4%
7%
2012 Shipments (m²)
Building
Transport
Appliance
Furniture
Miscel.
Stockists
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Paints systems in 2012
47kt25%
113 kt58%
33 kt17%
2012 Sales (193 kT)
Primers
Top Coats
Backing Coats
72%
12%11%
3%2%
Top Coats ( 113 kT)
POLYESTERPOLYURETHANE SYSTEMSPLASTISOLPVDFOTHERS
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Substrates vs. coatings since 1992
20 000
40 000
60 000
80 000
100 000
120 000
140 000
160 000
180 000
200 000
220 000
240 000
200
400
600
800
1 000
1 200
1 400
1 600
CC PRO
DUCT
SHIPMEN
TS (in m
io m
²)
Aluminium
Steel
Paint
PAINT SH
IPMEN
TS (in To
nnes)
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OC STEEL ‐ Imports into EU‐27 1995 2000 2005 2007 2008 2009 2010 2011 2012 2013 annualised
kT 23 288 336 1192 1101 677 898 1231848 736
0
200
400
600
800
1000
1200
1400
kt
Others
Ukraine
USA
Canada
Japan
Egypt
Vietnam
Switzerland
Russia
Morocco
Australia
Macedonia
Taiwan
Turkey
India
Korea
China
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OCS Monthly Imports (kt)
0
10
20
30
40
50
60
70
80
90
China
Korea
India
Taiwan
6 months Y‐o‐YChina: ‐ 93%India: +328 % Taiwan: + 66%Korea: +13%
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EU‐27 IMPORTS vs. EXPORTS (kT)
0
200
400
600
800
1000
1200
1400
2004 2005 2006 2007 2008 2009 2010 2011 2012
337 336
611
1192
1100
677
907
1231
848
406
515 506439
493 508439 431
554
IMPORTS
EXPORTS
Y‐o‐Y 2012 / 2011
Imports : ‐ 31 %
Exports: + 22 %
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I. ECCA and coil coating
II. The markets for coil coating
III. Sustainable innovation
Content
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Sustainable innovation
• REACH conformity & chromate‐free systems
• Functional and Textured coatings
• New outperforming substrates for outperforming prepainted steel
• Sustainable Buildings: energy through colour
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REACH conformity
REACH Conformity is mandatory in Europe
Targets for sustainable Coatings
• Heavy Metal free : no Chrome, Lead, Nickel
• Free of critical CMR raw materials : no carcinogenic, mutagenic, reprotoxic substances
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Identification as SVHC – proposalto be included in the candidate list
Inclusion in the
candidate list (of Annex XIV)
Prioritisation Latestapplication
date
SUNSET date
Lead chromates Aug 2009 Jan 2010 20/12/2010 for Jan 2012
21/11/2013 21/5/2015
Chromic Acid,ChromiumTrioxide
Aug 2010 15/12/2010 19/12/2011forFeb 2013
21/03/2016 21/09/2017
Strontium Chromate
Feb 2011 20/06/2011 Prioritisationrecommended by ECHA on 17/01/2013
Estimated2016
Estimated2017
Dichromium tris(chromate)
Aug 2011 19/12/2012 Prioritisationrecommended by ECHA on 17/01/2013
Estimated2016
Estimated2017
REACH UPDATECoatings for Prepainted Metal
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REACH : Chromates Fade‐out in 2017
Corrosion Protection
Chromate‐free systems (pretreatment, primers & topcoats) for prepainted metals (Steel/Aluminium) have been used in construction applications for 20 years...
Show comparable corrosion protection profile
Colours
Chromate‐free pigment substitutes are available and used
Some bright colour standards will need to be adjusted to new pigments
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Chromate‐freePrepainted Steel – Quality confirmed !
Longterm Durability• Outdoor Weathering Test in
corrosive Atmosphere– Bohus Malmön (S)
– Brest (F)
52Source: BASF Coatings
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Low Corrosion Impact after 5 Years in Brest & Bohus M.
53Source: BASF Coatings
Prepainted Steel from different Coil Coaterso Substrate: HDG (Z)o Coating Systems
5 µm Chromate-free Universal Primer20 µm Polyester & Polyurethane Topcoats
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Variable design
APPEARANCE :– Colour
– Gloss
– Surface finishing
‐ smooth
‐ grained, textured, embossed, etc ..)
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Appearance Examples
Smooth
Orange Peel primer
Orange Peel
TopcoatPrimer (or base coat)Substrate
Variable design
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Appearance Examples
Polymeric particles (polyamide)
Grained
Structured varnish
Structured
TopcoatPrimer (or base coat)Substrate
Variable design
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Appearance Examples
TopcoatPrimer (or base coat)Substrate
Wrinkled
Embossed
Embossedwith textured rolls
Variable design
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KEY PERFORMANCES – Formability
– Corrosion resistance
– UV Resistance
– Abrasion resistance
– Scratch resistance
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Key attributes & performances of prepainted metal
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Specific PERFORMANCES• Chemical resistance
• Reflectivity / Emissivity• cool roofs / urban heat island effect
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Functional coatings
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Specific PERFORMANCES• Anti graffiti
• Anti‐dirt / self cleaning
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Functional coatings
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ZincMagnesium :new outperforming substrate• Continuous innovation in substrate development to offer the most complete range suitable for industrialapplications
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ZM :new outperforming substrate
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• ZnAlMg coated steels are readily available in Europe and their superior performance is now well known on the market – Increased corrosion resistance compared to classical HDG in severe environments (e.g. chloride & highly alkaline)
Salt spray test:
20 µm coating per side
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ZM: new outperforming substrate
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• ZnAlMg coated steels are readily available in Europe and their superior performance is now well known on the market – Similar corrosion protection performance withlower metallic coating thickness
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ZincMagnesium :new outperforming substrate
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• ZnAlMg coated steels are readily available in Europe and their superior performance is now well known on the market – Improved cut‐edge protection
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ZincMagnesium :new outperforming substrate
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Standardization (EN10346 : Continuously hot‐dip coated steel flat products…) update with ZM ongoing
– Definition of the alloy: application of a zinc‐magnesium coating by passing the prepared strip through a molten zinc bath with aluminium and magnesium contents in sum of 1,5 to 8 % by mass
– Steel grades available– Alloy coating masses available– Coating finish– Surface condition
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New outperforming substrate for outperforming OCS
• ZM is an excellent substrate for coil coatedmaterial with balanced product properties.
• The use of ZM metallic coatings for coil coating has been validated by several national certification bodies e.g. DIBt (Germany), CSTB (France)
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Sustainable Buildings:energy through colour
• Cool Colors or Heat Absorbing Surfaces– material in the walls and
roofs that contribute to saving energy for cooling and ventilation
– prepainted metal solarcollector absorbing solarenergy anc converting it intouseable heat
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SSAB – Swedish Pavilion – Expo 2010
TataSteel ‐ Colorcoat Renew SC®
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In a nutshell …
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Coil coating is the best available technology for applying paint to metal
The process is environmental friendly
Prepainted metals have major advantagesover competing materials in terms of aesthetics, longevity, corrosion protection, quality and sustainability
Prepainted metals are 100 % recyclable atend‐of‐life
Continuous and sustainable innovation
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