Introduction to Coatings. Field Performance and the Application Process

Transcription

1 Introduction to Coatings Field Performance and the Application Process

2 Linetec is a Registered Provider with The American Institute of Architects Continuing Education Systems. Credit earned on completion of this program will be reported to CES Records for AIA members. Certificates of Completion for non-aia members are available on request. This program is registered with AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.

3 Learning Objectives Participants of this course will learn how different paint and anodize finishes rate when compared to architectural specifications. Participants will also learn about the application process to assure a quality product is provided. Length: 1 hour Credits: 1 LU/HSW

4 Copyright Materials This presentation is protected by US and International Copyright laws. Reproduction, distribution, display and use of the presentation without written permission of the speaker is prohibited.

5 Introduction to Coatings: Field Performance and the Application Process The Anodizing Process Anodize Specifications and Performance The Paint Process Paint Specifications and Performance The Powder Coat Process Summary Comparison of all Coating Types

6 The Anodize Process

7 What is Anodizing? Anodizing is the process of electrochemically controlling, accelerating and enhancing oxidation of an aluminum substrate. The anodizing process produces an oxide film that is uniform, hard and protects the rest of the aluminum substrate from deterioration. Electricity Chemicals Aluminum Aluminum Oxide Coating

8 Oxide Film Structure Anodic Pore Aluminum Oxide Layer Barrier Layer Aluminum The anodizing process thickens the natural oxide film resulting in a heavy aluminum oxide film of controlled thickness having the hardness similar to that of a sapphire (second hardest substance known to man).

9 Anodize Performance Avoids aluminum deterioration Extremely hard coating Similar to sapphire, second hardest substance on earth Semi-transparent coating

10 Anodizing Multi-Stage Process Racking Cleaning Etching Anodize Coloring Seal Process

11 Anodize Line A sophisticated computerized hoist system guides material through the anodize process

12 Weld Racking Typically used for stock length extrusions

13 Clamp Racking Typically used for cut to size and fabricated pieces

14 Fixture Racking Typically used for large volume, identical parts

15 Anodizing Process Cleaning Alkaline Cleaner Removes dirt, water, oils from aluminum surface Cleaning process does not remove grease or marker ink

16 Anodizing Process Etching Immersed in caustic or acid (eco-friendly) bath Produces a matte finish Removed minor scratches and minor die lines Will not remove all surface defects Etch quality is critical to final appearance because anodize is a semi-transparent coating Eco-Friendly Etch Process Hides small defects in the aluminum surface, allowing for anodizing of recycled/secondary billet Provides a frostier, matte finish Lower gloss level, reducing sunlight glare Aluminum removed during etch process is reduced by 80%, down to 0.5 mils Has the viscosity of water and less likely to collect in small recesses of aluminum extrusions

17 Anodizing Process Anodic Coating Immersed in 15% sulfuric acid Charged with electrical dc current Aluminum oxide layer formed known as clear or satin Immersion time = coating thickness Clear Anodize

18 Anodizing Process Coloring Champagne, bronze tones, black Known as electrolytic color or two-step color Color created by electro-deposition of tin All colors in a single tank Color dependent on the amount of tin deposited Alloy and temper of the aluminum also can affect color Amount of tin deposited depends on the time in the tank Lightest colors are the toughest to control

19 Anodizing Process Electrolytic or Two-Step Coloring Tin Deposit Anodic Pore Aluminum Substrate

20 Anodizing Process Seal (closing of the pores) Immersed in a high purity hydrothermal solution Protects anodic coating and coloring from weathering Closes and seals the anodic pores The proper sealing is absolutely essential to the satisfactory performance of the coating. The pores must be rendered nonabsorbent to provide maximum resistance to corrosion and stains. This is accomplished through a hydrothermal treatment in proprietary chemical baths

21 Anodizing Process Quality Control Analysis Champagne anodize range samples Dark bronze anodize range samples

22 Anodizing Process Quality Control Tests Color Visual test to range samples Spectrophotometeter (no recommended) Coating Thickness Isoscope Chemistry Autotitrator

23 Anodizing Specifications and Performance

24 AAMA Anodizing Specification Spec Number: AAMA Class I Class II End Use Exterior Interior or exterior w/regular maintenance Film Thickness 0.7 mils 0.4 mils Salt Spray Resistance 3000 hours 1000 hours Color Retention 10 yrs: Fade = 5 Delta E 10 yrs: Fade = 5 Delta E

25 Industry Product Labels Class I Class II Clear 215R1 204R1 Two-step color Champagne Light Bronze Medium Bronze Dark Bronze Class I Extra-dark Bronze Black

26 Strengths of Anodize Durability, abrasion resistance Metal appearance Excellent weatherability (Class I)

27 Limitations of Anodize Limited color choice Will not hide surface defects on aluminum (caustic etch process) Finish will vary depending on alloy of the aluminum Difficult to match anodized sheet with anodized extrusions Strong acids/alkalis will quickly deteriorate the aluminum anodized surface Field repair is difficult at best, and sometimes not possible Chemical attack from acid or alkaline materials - most common occurrence is encountered when mortar or muriatic acid is allowed to dwell, even for a short time

28 Points to Specify for an Anodized Finish Refer to AAMA Class I or Class II Color state two-step electrolytic Color consistency range <5 delta E Eco-friendly (acid) etch process creates an aesthetically appealing "frostier" appearance that helps hide small defects in the aluminum

29 The Painting Process

30 What is Painting? Painting is the application of a protective, decorative organic coating to the surface of a substrate Spray Coating Method Horizontal paint line Vertical paint line Coil Coating Method

31 Painting Multi-Step Process Racking Pretreatment Painting Curing Quality Assurance

32 Racking

33 Pretreatment Process Multistage Process Cleaning Remove surface contaminants, water soluble oil Conversion Coating Ensures adhesion of the paint Adds corrosion protection Chrome or chrome-free

34 Paint Application Primer coat (not all paints require a primer coat) Color coat / Top coat Clear coat (not all paints require a clear coat)

35 Automatic Spray Bells

36 Hand Spray Reinforcement

37 Paint Line in action

38 Paint Cure Process Achieve through baking in a convection oven Material must reach peak metal temperature Between 350 F to 450 F depending on paint type Precision of cure is important for consistent color and gloss

39 Pigment and Resin left on the Substrate Solvent escapes during baking Resin surrounds pigment particles binding them to the substrate Primer Substrate

40 Quality Control Tests Mil thickness Color Gloss

41 Quality Control Tests Spectrophotometers This instrument measures color. This is done to ensure the project material matches the approved color standard. BYK-Gardner Color-Guide Gloss This unique instrument simultaneously measures color and gloss to make sure the material meets the specification.

42 Quality Control Tests

43 Test Panels Test panels can be run with project material. The AAMA specification tests are then done on these sample panels to assure a quality product. The test results should be kept on file so they can be referenced in the event of a job site issue. Some of the tests done are: Impact Resistance Adhesion (Boiling Water) Mortar Resistance Acid Resistance Mil Thickness Pencil Hardness

44 Job Panels are sent to South Florida for weathering tests 70% Fluoropolymer paint panels cannot fade more than 5 Delta E s in a period of 10 years, and they cannot chalk more than a rating of 8 in a 10 year period. These are critical factors to assure a long-lasting and maintenance free finish on architectural products.

45 Environmental Considerations of Paint Solvent Vapors (VOC) Should be sprayed and cured in a 100% enclosed capture area Routed to, and destroyed by, a thermal oxidizer

46 Environmental Considerations of Paint Landfill Waste Reduction Applicator should have wastewater recovery system to minimize waste chrome Remove all paint-related waste from landfill by fuel-blending and reusing as heat energy Utilize paint solvent recycle program

47 Paint Specifications and Performance

48 AAMA 2603 Paint Specification AAMA 2603 South Florida Weathering Color Retention 1 year slight fade Chalk Retention 1 year slight chalk Gloss Retention No specification Erosion Resistance No specification Dry Film Thickness 0.8 mils minimum Pretreatment System Chrome or Chrome Free Accelerated Testing Salt Spray 1,500 hours Humidity 1,500 hours AAMA 2603 is typically an Interior Specification. Baked Enamel paints meet the AAMA 2603 spec. The baked enamel coatings are harder than the PVDF (Fluoropolymer) coatings and are used quite often for interior application where color retention is not required. These paints are less expensive than PVDF paints, but once again, have poor resistance to color fading and chalking.

49 AAMA 2603 Baked Enamel Coatings Attributes Very good hardness Achieves AAMA 2603 (only) Low cost Limitations Poor color and gloss retention Fair chemical resistance Applications Interior products

50 Baked Enamel Systems Manufacturer Trade Names Akzo Nobel Acro-Bond Plus PPG Duracron Polycron III Valspar Flurocryl Dynapon

51 AAMA 2604 Paint Specification AAMA 2604 South Florida Weathering Color Retention 5 years 5 Delta E Chalk Retention 5 years Chalk = 8 Gloss Retention 5 years 30% retention Erosion Resistance 5 years 10% loss Dry Film Thickness 1.2 mils minimum Pretreatment System Chrome or Chrome Free Accelerated Testing Salt Spray 3,000 hours Humidity 3,000 hours AAMA 2604 is an intermediate specification. A typical paint to meet this spec would be a 50% Fluoropolymer. A typical application for this paint would be storefront, doors and other high traffic areas. This finish will provide you with good color and gloss retention. It will also provide good hardness and reasonable abrasion resistance.

52 AAMA % Fluoropolymer Coatings Attributes Good hardness Good color and gloss retention Achieves AAMA-2603 and AAMA-2604 Moderate cost Limitations Limited gloss range (25-35% reflectance) Applications Cost-sensitive exterior applications (storefronts, doors, high-traffic areas) Kynar and Hylar are not finished paints, they are trade names for the PVDF resin used in highperformance Fluoropolymer paint coatings

53 50% Fluoropolymer Coatings Manufacturer Trade Names Akzo Nobel Aluma-A-Star 50 Aluma-Escent PPG Acrynar FX Valspar Acroflur Acrodize

54 AAMA 2605 Paint Specification AAMA 2605 South Florida Weathering Color Retention 10 years 5 Delta E Chalk Retention 10 years Chalk = 8 Gloss Retention 10 years 50% retention Erosion Resistance 10 years 10% loss Dry Film Thickness 1.2 mils minimum Pretreatment System Chrome or Chrome Free Accelerated Testing Salt Spray 4,000 hours Humidity 4,000 hours AAMA 2605 is the high-end exterior specification. A typical paint to meet this spec would be a 70% Fluoropolymer. These finishes exhibit outstanding resistance to humidity, color change, chalk, gloss loss, and chemicals. A typical application for this finish is large monumental architectural projects.

55 AAMA % Fluoropolymer Coatings Attributes Excellent color and gloss retention Excellent chemical resistance Achieves AAMA-2603, AAMA-2604 and AAMA-2605 Limitations Limited gloss range (25-35% reflectance) Fair hardness Higher cost Applications Exterior products Recommended for monumental projects Kynar and Hylar are not finished paints, they are trade names for the PVDF resin used in highperformance Fluoropolymer paint coatings

56 70% Fluoropolymer Coatings Manufacturer Trade Names Akzo Nobel Trinar Trinar Ultra PPG Duranar Sunstorm Duranar XL Sherwin Williams Shernar Valspar Fluropon Fluropon Classic Fluropon Classic II Flurospar

57 Fluoropolymer Paint Coatings Kynar 500 & Hylar 5000 are types of fluoropolymer or PVDF resin used in a 70% PVDF resin based coatings that meets the AAMA 2605 specification Kynar 500 & Hylar 5000 have a long standing proven track record Kynar 500 & Hylar 5000 are the resin part of the paint coating

58 Resin System When people describe paint systems, they are typically referring to the resin system incorporated in the paint

59 Resin System The resin system determines the properties and performance of the paint Typical gallon of 70% PVDF liquid paint 10% pigment 20% resin 70% solvent 70% fluoropolymer paints 70% of the resin component is 50% fluoropolymer paints 50% of the resin component is Baked enamel 100% of the resin component is acrylic or polyester

60 Weatherability Chalking Fading This is an actual warehouse painted in 1981 with different resin systems

61 What Causes Chalking Chalking is caused by a degradation of the resin systems at the surface of the finish, due predominantly to Ultra Violet (UV) rays. As the resin system breaks down, resin particles along with imbedded pigment particles lose adhesion and take on a white appearance. Chalking is measured on a numerical scale. The higher the number, the better the chalking performance.

62 Failure in the Resin System Causes Chalking Examples of Chalking Surface of the paint is breaking down (able to wipe off with your hand) A tree brushing against this building has rubbed the paint off because it had chalked

63 What Causes Color Fade Fading is caused when substances in the environment attack the pigment portion of the paint and cause the color to change. Paints that have a high resistance to fading have a lower reading.

64 Failure in the Resin System Causes Color Fade

65 Failure in the Resin System Causes Color Fade

66 Warranty Information Paint Type Chrome Pretreatment Non-Chrome Pretreatment Valspar Fluropon PPG Duranar Akzo Nobel Trinar Up to a 20 year warranty including adhesion Up to a 20 year warranty including adhesion Up to a 20 year warranty including adhesion Additional testing and chrome primer must be used to receive a 20 year warranty that includes adhesion No warranty on seacoast projects. Up to ten years on other projects No adhesion warranty unless Akzo has tested and approved the pretreatment system Fluoropolymer paint suppliers promote Chrome Phosphate pretreatment for the maximum corrosion protection available. Most field failures trace back to improper pretreatment, says industry expert Manny Mayer. He puts the percentage at 90% or greater

67 Points to specify for a painted finish Refer to AAMA-2605, AAMA-2604, or AAMA-2603 Name 70% PVDF resin-based coatings for exteriors Specify minimum 40 mg/sq ft chrome pretreatment to ensure maximum long-term adhesion

68 Environmental Considerations VOC s Specify all paint applicators must utilize a solvent capture system and thermal oxidizer Chrome Specify all paint applicators must use wastewater recovery system to minimize chrome waste, and applicator complies with all hazardous waste disposal regulations

69 Strengths of Paint Vast choice of color Excellent exterior performance (70% PVDF) Field touch-up and repainting Small batch and custom colors fast and cost effective Seacoast performance Over 40 years of success in North America Available with antimicrobial protection infused in the coating

70 Limitations of Paint Higher cost Inconsistent appearance of metallic paints Susceptible to scratching, especially the highest-performing 70% PVDF coatings

71 Powder Coating

72 What is Powder Coating Same basic process as liquid painting With the exception of using dry powder rather than wet paint A mixture of finely ground particles of pigment and resin, which are sprayed on the surface to be coated The dry powder melts and blends in the cure oven

73 Powder Coating Line

74 Points to Specify Uses the same AAMA specifications as liquid paint. AAMA-2605, AAMA-2604 and AAMA-2603 Specify minimum 40 mg/sq ft chrome pretreatment to ensure maximum long-term adhesion

75 Powder Coat Trade Names AAMA 2603 AAMA 2604 AAMA 2605 Akzo Nobel Interpon D1000 Interpon D2000 Interpon D3000 IFS Coatings Ecuracote 03 Ecoset 04 Fluorset FP / Ecoset 05 PPG Envirocron Duranar Sherwin Williams Powdera 3000 Powdera 4000 Powdera 5000 Spraylat Arc 2001 Decaflon Tiger Drylac Series 29 / 17 Series 58 / 68 Series 75 TCI Series Series

76 Strengths of powder coating Hardness and scratch resistance particularly for commercial products like lawn mowers, bike frames and appliances Environmentally Friendly minor VOC emission Large job cost may be equal or slightly less than a 70% PVDF liquid coating

77 Limitations of Powder Coating Small custom color jobs Warranty - varies by supplier. Many are more restrictive and limited as compared to 70% PVDF liquid coatings Metallic coatings can only hold 30% of the metallic flake content as compared to AAMA 2605 liquid coatings Touch up air-dry paint must be matched in a liquid paint for touch-up and field repairs Samples and color matches no in-house blending of powder coatings Lead times can be up to 4 weeks

78 Touch Up Paint Does not have the same adhesion or durability as the factory applied coatings Will exhibit chalking and fading characteristics noticeably faster Should be used as sparingly as possible Intended only to cover small blemishes or to touch up exposed cut ends on fabricated parts

79 Summary Comparison of All Finish Types

80 Weathering Performance Finish Performance Comparison Finish Options Paint Systems Anodize Systems Baked Enamel 50% PVDF 70% PVDF Class II Class I Color & Gloss Poor 1 Good 2 Excellent 3 N/A Excellent Chalk Resistance Poor 1 Good 2 Excellent 3 N/A Excellent Color Options Extensive Extensive Extensive Few Few Gloss Options Hardness Very Good Good Fair Very Good Excellent Salt Spray Resistance Poor Fair Good Fair Very Good Chemical Resistance Fair Good Excellent Fair 5 Good 5 Effect of Poor Quality Substrate Moderate Moderate Moderate Significant Significant Initial Cost Low Moderate High Very Low Low 1 Meets AAMA Meets AAMA-2603 and AAMA Meets AAMA-2603, AAMA-2604 and AAMA Dependent solely on the individual substrate 5 Except for highly alkaline solutions very poor performance

81 Questions

82 Include this guide specification for high-performance architectural coatings in your Master Spec

83 Additional offers by Linetec Samples for Specified Projects Restoration and On-Site Painting Antimicrobial Protective Coatings Copper Anodize Finishes

84 Thank you for your time and attention