Architectural Coil Market Coatings

Transcription

1 Welcome to Valspar s course on Architectural Coil Market Coatings. We re glad you ve joined us today. Let s get started! Architectural Coil Market Coatings HS UI GP H E RP IEO R F OP ER RM FA ON RC ME A NR C E H AI TR EC CH TI UT ER CA TL UC RO A L T CI NO GA ST I N G S 1

2 We have five learning objectives today: CEU Credit Course Learning Objectives 1. Identify advantages of building with metal. 2. Provide overview of the coil coating process and the benefits of pre-paint. 3. Identify coatings components and their role in the coating system. 4. Describe coating manufacturing process and coating chemistry. 5. Identify industry standards relative to performance requirements of coatings for metal building components. First, I ll talk about the advantages of building with metal. Next, I ll describe the coil coating process and the benefits of prepaint. Then, I ll discuss the components of coatings and their role in the coating system. From there, we ll move into the coating manufacturing process and talk about coating chemistry. Then, I ll provide an overview of the industry standards related to performance requirements. 2

3 Let s start with the first learning objective: Identifying the advantages of building with metal. Learning Objective One Identify advantages of building with metal. 3

4 There are many benefits to building with metal. First, metal is economical. Metal is also a sustainable building material with a sustainable manufacturing process. Benefits of Building with Metal Economical Sustainable Versatile Beautiful Metal products provide versatility in both new and retrofit projects. Metal also provides a lot of beauty. Let s dive into each one of these benefits in more detail. V A L S P A R 4

5 First, let s talk about the economics of building with metal. Pound for pound, metal is very cost-effective for roofing and siding material. Metal is Economical Cost-effective for roofing and siding Installation time-savings Strong and durable for service life Lower maintenance Long-lasting Higher return-on-investment over the product s life cycle Metal is easier and faster to install, which saves contractors time. Metal is also very strong and damage resistant to high winds, hurricanes and hail compared to asphalt shingles or wood siding. And, metal can be designed to withstand severe acts of nature, translating to lower insurance costs. Metal typically provides lower maintenance costs because it lasts longer than traditional building materials such as wood, stucco, brick and asphalt. As a result, metal delivers better return-oninvestment than other building materials. Today's metal construction products are protected by highly durable coatings so they can deliver decades of service. V A L S P A R 5

6 Next, let s talk about sustainability. Metal is Sustainable Contains 25 to 95% recycled materials 100% recyclable Decreased cooling expenses with Solar Reflective coatings Tax benefit: Leadership in Energy and Environmental Design (LEED) Metal is one of the most energy-efficient and sustainable building materials available. It typically contains 25% to 95% recycled materials. Metal is virtually 100% recyclable at the end of its life. The soda can you drink from today can be recycled into an airplane you can fly in tomorrow. Insulated metal panels with solar reflective coatings stay much cooler, decreasing cooling expenses and keep building occupants more comfortable. Traditional dark-colored roofing materials can reach 185 degrees in the summer, transferring an enormous heat load to the house. Highly reflective roofing surfaces can trim degrees off the temperature, which can translate to a 40% reduction in energy use. Essentially, metal panels don t get as hot and cool down more quickly. Owners can earn 1 LEED credit for solar reflective coatings and a second LEED credit when using metal with a high percentage of recycled content. LEED credits can deliver tax benefits as well. V A L S P A R 6

7 Metal is also a very versatile building material. Whether the project is new or retrofit, designers and building owners can achieve virtually any look with a variety of coating finishes available. Metal is Versatile New or retrofit buildings Versatile design options for roof or wall systems Works with renewable energy systems Reduced environmental impact Long life span V A L S P A R Metal Roof Systems can be installed on a new building or over an old roof. This fixes roof problems and updates the appearance quickly and cost effectively. A new metal roof also improves the building s thermal efficiency. Metal Wall Systems can make a new building stand out as a landmark or signature piece within a city or community. And, metal wall systems bring life to old buildings. Retrofit metal walls are durable and look great. They are lightweight, so there is little or no alteration required to existing structural elements. Builders can choose from preformed metal, insulated metal panels, composite materials or solar thermal walls to allow for maximum solar heat recovery. Whether used on a new building or a retrofit, metal can reduce the environmental impact of a building and deliver a long lifespan. 7

8 Metal has emerged as the material of choice in many roof and wall applications for its beauty. Metal is Beautiful Substrate options for roof and wall systems Aluminum Copper Steel Zinc Wide range of colors, shapes, seams, styles, sizes, profiles and textures Today s high-performance architectural coatings perform well on Aluminum, which is critical for highly visible roof applications. Copper is also a popular choice among metal types for its longevity. Copper roofs can last decades to centuries. Steel is considered a universal building product because of its strength, versatility, durability and economic value. The American Iron and Steel Institute reports that steel roof construction is used in nearly half of all low-rise commercial, industrial & institutional buildings. Building owners and architects are increasingly turning to Zinc as the metal of choice. It never fades, is noncorrosive and is environmentallyfriendly with 100%-clear water runoff. V A L S P A R 8

9 There are several myths about building with metal that I want to dispel today. #1 Metal is noisy when it rains. #2 You can t walk on a metal roof. Dispelling Top 10 Myths About Metal MYTH 1 MYTH 2 Noisy in the rain Can t walk on MYTH 6 MYTH 7 Is heavy Prone to hail damage #3 Metal will rust. #4 Your metal roof is more likely to get struck by lightning. #5 Metal roofs are hot. #6 Metal roofs are heavy. #7 Metal roofs and siding are prone to hail damage. MYTH 3 Will rust MYTH 8 Paint will flake off #8 Paint will flake off. #9 Metal will get dirty. MYTH 4 Get struck by lightning MYTH 9 Will get dirty #10 Coating colors and textures are limited when building with metal. MYTH 5 Is hot MYTH 10 Limited colors Let s look at each of these myths in more detail. V A L S P A R 9

10 The first myth is that metal is noisy when it rains. FACT: Most metal roofs and wall panels don t make any more noise in the rain than other building materials. In fact, they may be less noisy. MYTH 1: Metal is Noisy in the Rain Metal roofs are typically installed on solid substrates with an underlayment that prevents reverberation and deadens the sound. The effect is similar to the difference between hitting a cymbal suspended on a stand and a cymbal laid on carpeting. Sounds are muffled. V A L S P A R 10

11 The second myth is that you can t walk on a metal roof. MYTH 2: Can t Walk On Metal Roof FACT: Metal roofs are very durable. You can safely walk on them without causing damage. In contrast, foot traffic can damage traditional shingles, especially in cold weather. V A L S P A R 11

12 The third myth is that metal will rust. FACT: Metal building materials feature protective galvanized coatings that are applied over the base metal and have industry-leading warranties. MYTH 3: Metal Will Rust For example, the life expectancy for steel wall panels can be up to 40 years with today s advanced color systems that resist fading. Recoating a steel roof can add additional years. In contrast, warranties for composite roofing range from 15 to 30 years. V A L S P A R 12

13 The fourth myth is that metal is more likely to get struck by lightning. MYTH 4: Metal Will Get Struck by Lightning FACT: Lightning strikes the highest point in the area regardless of the material. Metal actually reduces the threat of fire from lightning because it serves as an electrical conductor, and it s noncombustible. In contrast, for composite roofing, lightning rods are the only protection available. V A L S P A R 13

14 Myth number five is that metal is hot. MYTH 5: Metal is Hot FACT: With today s technology, coatings help metal stay cool to the touch, whether it s metal used on playground equipment or on a metal building. Metal roofing and wall panels come in a variety of cool colors that reflect solar heat. They cool down more quickly than asphalt shingles, reducing heat load on a home. In contrast, composition shingles collect and store radiant heat from the sun, staying warm and permeating into the attic space of the home or building long after sunset. Metal is good in all climates. In the North, for example, a metal roof can reduce solar gain in the summer months and save on cooling costs. In the winter, snow melts faster and slides off the roof. By using solar-reflective, high performance coatings, metal roofing can save a home or building owner up to 25% in cooling energy costs compared to a dark-gray asphalt shingle. Most metal roofing achieves or exceeds ENERGY STAR ratings published by the U.S. Federal Government and can contribute to earning LEED points. V A L S P A R 14

15 Myth number six is that metal is heavy. MYTH 6: Metal is Heavy FACT: Metal roofing and wall panels can be much lighter than other building materials. For example, metal roofs are just half the weight of asphalt, and 75% lighter than concrete tile, fiber cement shakes or slate. Composition shingles can weigh as much as three pounds per square foot. This means that a 3,000 square-foot roof can weigh as much as 9,000 pounds compared to 4,500 pounds for metal. Often, a second layer of shingles is installed when reroofing, which doubles the weight of shingles to 18,000 pounds. That s a heavy load! Since metal roofing is so much lighter, it puts less stress on the building structure. Beyond the weight advantage, steel roofs and wall panels are stronger, more storm-resistant and longer-lasting. V A L S P A R 15

16 The seventh myth is that metal is prone to hail damage. MYTH 7: Metal is Prone to Hail Damage FACT: Today s metal building components are tough and less likely to be damaged by hail and wind than other building materials. For example, steel roofing and wall panels are very tough and highly resistant to hail and wind damage. Some insurance companies even provide a reduced rate when metal building materials are used. In the hail belt regions of the U.S., many metal roofing products have the highest rating granted by insurance for impact resistance and hail damage. V A L S P A R 16

17 Myth number eight is that paint will flake off metal if the part is painted first and then bent and formed. MYTH 8: Paint will flake off FACT: Metal coatings can be formulated with extreme flexibility. When the painted coil metal is formed into a part, the coating can easily flex and look great with no flaking or cracks. V A L S P A R 17

18 Myth number nine is that metal will get dirty. MYTH 9: Metal Will Get Dirty FACT: Metal roofing and wall panels that feature high-quality coatings are dirt resistant and will stay looking great. On a roof, some composition shingles are extremely susceptible to algae and mold growth. Metal roofing actually deters algae and mold growth. The roof stays looking much newer and cleaner than a traditional roof. V A L S P A R 18

19 The last myth is that coating colors and textures are limited when building with metal. MYTH 10: Limited Color Options FACT: There is an unlimited range of colors, gloss levels, textures and looks available today in metal building materials for roofing and wall panels. Metal roofs are available in many solar-reflective colors that meet ENERGY-STAR ratings for energy efficiency and contribute to LEED points. V A L S P A R 19

20 We ve just completed the first Learning Objective: identifying the advantages of building with metal. COMPLETED: Learning Objective One Identify advantages of building with metal. V A L S P A R 20

21 Let s move on to our second learning objective today. I ll be providing an overview of the coil coating process and the benefits of prepaint. Learning Objective Two Provide overview of the coil coating process and the benefits of pre-paint. 21

22 There are many reasons to coat metal. Why Metal is Coated AESTHETICS PROTECTION ENERGY SAVINGS First let s talk about aesthetics. Coatings help enhance the beauty of a building with unlimited colors and finishes available to create a unique look. Functionally, coatings provide important protection against corrosion caused by weathering. This helps keep metal building materials looking great for years. And, coatings are great at hiding defects on metal so the surface looks smooth and beautiful. Coatings also save energy. Solar-reflectivity coatings for metal roofs can deliver up to 25% in annual cooling savings. HIDING METAL DEFECTS 22

23 There are two main types of coating applications we ll cover today. Architectural Coating Applications COIL (Pre-paint) Coating applied to metal Part fabricated after metal is coated On the top of the slide, you will see a large roll of metal coiled up. The process for coating this type of metal is known as coil coatings or prepaint because the coating is applied to the metal before parts are fabricated. For metal parts made by extrusion, the parts are first made and then coated. Let s take a deeper look at each of these processes. EXTRUSION Aluminum parts are extruded Coating applied to parts 23

24 Here s a snapshot of the continuous coil coating process. Continuous Coil Coating Process In the picture on the left, you will see a very large roll of the bare metal substrate being delivered from the manufacturer s rolling mill to a coil coating facility. On the right, you can see the metal being painted. 24

25 Here s a quick overview of the coil coating process. After the metal is delivered, it is cleaned and then coated. Overview of Automated Coating Process Metal delivered in coil roll Fed continuously through coating roller Both sides coated at same time Wide range of coating types Uniform gloss, color and thickness Metal easily re-coiled The metal unrolls from the coil in flat sheet form and moves very, very quickly on the coating line up to 700 feet per minute. Both sides of the metal are coated at the same time with the roller system helping to provide uniform paint application. A range of coatings can be applied in various colors, gloss levels and thickness. One of the big benefits of the coil coating process is how uniform the finish is on the sheet of metal. It turns out beautifully and is very durable. Once the coating is dried and cured, the metal is easily re-coiled and sent to the component manufacturer to produce metal parts. 25

26 Coil coating lines represent an investment of tens of millions of dollars. On the left you can see the coil being fed into the machine, where it is Uncoiled. Typical Coil Coating Line In Pretreatment, alkaline cleaners, mechanical brushes and fresh water rinses are used to remove surface contaminants and mill oils that prevent corrosion during transit and storage. Pretreatment also improves surface reactivity of the metal substrate, paint adhesion and corrosion resistance. Next, Primers are applied to both sides of the metal to aid in paint adhesion and corrosion resistance. Finish Coats or Top Coats are applied after the prime coat to provide: - The desired physical appearance and aesthetics; - Weathering characteristics, like chalk, fade and gloss retention; and - Physical properties, like hardness and flexibility. Backers provide corrosion protection, a consistent bottom side appearance and protection against abrasions during transit. Once the coating is cured, the metal is re-coiled and sent to the component manufacturer. 26

27 There are numerous benefits that come from the prepaint process. Benefits of Coil Coating Pre-Paint Process Centralized Operations 98% Solvent Capture Exceeds EPA Standards Most efficient, effective and environmentally-friendly method to pre-clean, pre-treat, pre-prime and pre-paint metal First, the coating process is centralized at a coil coater using a high-tech coating line. The metal part manufacturer doesn t have to have an in-house paint shop, which eliminates labor, inventory, equipment and operating costs. Second, environmental issues are concentrated, controlled and even eliminated. In coil coating facilities, 98% of the solvents are captured. The coating curing ovens burn the solvents as fuel, saving energy and eliminating pollutants. Third, the coil coating industry is subject to the highest EPA standards and the prepaint process exceeds these stringent standards. In short, the coil coating prepaint process is the most efficient, effective and environmentally-friendly method to pre-clean, pre-treat, pre-prime and prepaint metal and deliver a beautiful, high quality finish. 27

28 There are several myths floating around about prepainted metal that I would like to dispel today. First, there is the mistaken belief that it is expensive. I ve just debunked that myth. Pre-Painted Metal Myths Expensive Metal can t be joined Difficult to form Corrode easily along cut edges Challenging to handle Second, some people believe that you cannot join pieces of metal together once they are coated. This is not true. It s easy to do. Third, there is a believe that it s hard to form a metal part into shapes once it is coated. Coatings can actually be formulated with a lot of flexibility so they can bend while being formed. Another belief is that these parts will corrode easily along cut edges. If this were true, manufacturers would have quit using prepainted metal a long time ago. Instead, prepaint is gaining in popularity because of its many benefits. Finally, there is a believe that coated metal is a challenge to handle without damaging it. However, the coatings are tough and resist damage. Millions of parts are manufactured every day from prepainted metal. 28

29 What Happens After Metal is Coated? Coil coated metal can be FORMED slit cut profiled molded corrugated into variety of shapes for metal building products and systems Now, you might be wondering what exactly you can do to a coated metal. You can slit, form, cut, profile mold and corrugate metal that has a coating on it. Prepainted metal is used in roofing and cladding, wall panels, appliances, furniture fittings, engineering components and other finished goods. In the photo, you can see an example of a wall panel being manufactured. 29

30 An important part of a Coil Coating is the great performance it provides. Overall Benefits of Coil Coatings It protects metal building components from dirt, stains and mars. Think about the wear and tear of a store entryway with people going in and out all day long. The coating needs to be tough enough to withstand this environment. Coatings are formulated to defy humidity, corrosive salt spray, heat and UV rays. Coatings also help resist chemicals, oxidization and corrosion. Performance Protects from dirt, stains and mars Defies humidity, salt spray, heat and UV rays Resists chemicals, oxidation and corrosion Aesthetics Outstanding color retention Consistent finish Variety of finish options and special effects From an aesthetic standpoint, coatings need to be beautiful. Available in thousands of colors, they provide outstanding color retention so the building stays looking great for years. Coatings deliver a very smooth and consistent finish. And, there are many finish options and special effects, ranging from textures to a copper look. 30

31 Since the prepaint process meets and can exceed strict environmental standards, coil coated metal continues to gain in popularity. Environmental Benefits of Coil Coated Metal Meets strict environmental standards Saves energy Made from recycled content Can be recycled The coating process is very efficient with little paint wasted. The application process allows coaters to capture and destroy solvents, which are used to fuel the oven that cures the coating. Burning solvents reduces energy costs on the product line. The metal is made from recycled content and metal products are recyclable at the end of their service life. All of these factors work together to deliver great environmental benefits. 31

32 Specialty coatings can differentiate products from the competition. This list shows just a few examples of specialty coating options in the market today, with more options being developed each year. Specialty Coil Coatings for Differentiation Antimicrobial Fingerprint Resistant Non-Skid Solar Reflective Red-List Compliant Damage Resistant Textured Special Effects 32

33 Let s take a look at a few of these specialty coatings. Coating Formulated with Specific Qualities More flexible for bending Fingerprint resistant for easier cleaning When formulating a coating, it s good to know what type of products will be manufactured with the coated metal. On the top left, you see a heating/cooling grille. The coating used on this metal part was formulated with a lot of flexibility so the metal would bend easily when the part was manufactured. On the top right, fingerprint-resistant coatings are a key selling feature on stainless steel appliances. Who wouldn t want this benefit in their kitchen? This coating provides manufacturers with a huge selling feature on appliances. Skid resistant for truck-trailer floor More flexible for shaping The photo on the lower left shows a truck-trailer flatbed, which can become extremely slippery when wet. Non-skid coatings deliver a safer floor bed to walk on. In the lower right, you see very large curved panels on a building. This metal shape requires a lot of flexibility in the coating for shaping. 33

34 With that, we ve completed learning objective two. I ve provided you with an overview of the coil coating process and the benefits of prepaint. COMPLETED: Learning Objective Two Provide overview of the coil coating process and the benefits of pre-paint. 34

35 Let s move on to learning objective three identifying coating components and their role in the coating system. Learning Objective Three Identify coating components and their role in the coating system. 35

36 Color sells and the right color sells even more. Color is consistently a key selling feature. Introduction to Color and Architectural Coatings Color consistently a key selling feature Color choices historically conservative Growing interest in the power of architectural color Color trends drive bolder color choices Unique opportunity for high performance architectural coatings Historically, building owners would tend to choose more neutral colors that wouldn t fade as fast and that would ensure the building didn t look outdated in a few years. As a result, color choices have been more conservative with a strong use of whites, beiges, bronzes, metallics, blacks and grays. Now, there s a trend to use more color and bolder color. This is providing an opportunity for manufacturers of high performance architectural coatings to formulate brighter colors that still deliver the long-term performance and durability expected in coatings. 36

37 The three main coating ingredients are Pigments, Resins and Solvents. The percentages you see can vary and are typical of a PVDF coating. What is a Coating? Comprised of three principal ingredients: 15% 35% Pigments Resin Additives: Control foam, flow, leveling Viscosity Modifiers: Improve settling Catalysts: Accelerate a chemical reaction Percentages vary by product type and color. 50% Solvents Pigments supply the color and opacity to hide the substrate so you get nice even color without show-through. Resins are the glue or binder that hold the coating together and protect the pigment. We generally describe the coating based on the resin used, which determines the durability and performance. Resin also offers properties such as flexibility on the coated substrate so it doesn t crack as the substrate flexes. Solvents are used as a thinner to make the coating easier to apply and to ensure a nice smooth surface. Additives can be added to paint to help it flow smoothly and to evenly disperse the pigments. Additives also provide special effects like texture, mar or abrasion resistance. High performance coatings typically have minimal additives because they can affect durability. Viscosity modifiers improve settling when a coating is applied. Catalysts can accelerate a chemical reaction. 37

38 Introduction to Pigments Blended to create desired color to suit aesthetics Types of pigments Organic Inorganic Specialty pearlescent and color-shifting Solar Reflective (SR) Depending on application and desired color, sometimes each type of pigment is used in same formula Organic Inorganic Pigments are added to paint to provide color. There are several different pigment types. In most colors, different types of pigments are blended to create the desired color organic pigments, inorganic pigments and in some cases, specialty pigments such as pearlescent or colorshifting, or even solar reflective pigments. Pigments also offer additional properties such as total coverage or hide which is the ability of the coating to cover the substrate so you have uniform and consistent color. There are also select pigments, especially pigments that are used in the primer, that offer corrosion resistance. These pigments are particularly good to use if you have a project in an aggressive environment where there are industrial chemicals, or the building is near the ocean airborne salt-spray. The coating system will have the ability to resist corrosion with these corrosion-inhibiting pigments. 38

39 Organic Pigments Colors can be very bright with vivid appearance Carbon-based Often made from petroleum compounds Less hiding power than inorganic pigments Poor weathering Low heat resistance Organic Colors from organic pigments tend to be more bright and vivid. You ll get brighter reds, greens and blues. They are carbon-based and often made from petroleum compounds. They have less hiding power they are more transparent so there is more show-through due to the smaller particle size of organic pigments. You have to load the formulation with a higher level of organic pigments. Another factor you want to consider is that organic pigments don t weather as well. They allow UV light and oxygen to penetrate, which breaks down the chemical bonds more quickly. They are not as heat resistant. You will see some degradation of color when these types of coatings are used. A lot of residential coatings use these types of pigments more so than high-performance coatings. Typically, organic pigments would be combined with inorganic pigments when formulating a highperformance architectural coating to make sure the right color and durability can be achieved. 39

40 Inorganic Pigments Mineral-earth type pigments are very simple and naturally occurring colored substances Manufactured from mineral compounds that are mainly complex metal oxides Have superior: Color stability Weather resistance Heat resistance Chemical resistance Inorganic Inorganic pigments are manufactured from naturally-occurring mineral compounds that are mainly complex metal oxides. Their color stability is far better, and they are more heat resistant and chemical resistant. They are also more resistant to acid rain and cleaning compounds. Colors coming from inorganic pigment are less bright. As you can see here, they are more of your earth-tone colors. In the past, there were some very bright colored mixed metal oxides in use. But today, they find very limited use due to the toxicity of the lead and cadmium compounds. Most high-performance coatings don t use the bright colored inorganic pigments anymore. Ceramic pigments, a subset of inorganic pigments, are an extremely well-performing pigment system. They have good color stability in heat, and they weather well. Ceramic pigments got their name because they are stable at the firing temperatures of molten glasses. These pigments can be used in ceramics, architectural coatings and other coatings. 40

41 There are more and more new pigment opportunities and special application processes that the coating industry is using to achieve richer, deeper colors, more texture and intense sparkle. Special Effects Pigments Prints Specialty Textured Mica/Metallic For example, here you see a series of Special Effects Pigments. On the upper left, you can see Prints these looks are achieved through the application process. The next set of images to the right shows Specialty pigments. They have different degrees of color and sparkle. Another interesting look is in on the lower left of the screen with the textured products they have a wrinkled look. This look has been very popular in the metal roofing industry. Then, you have your mica/metallic pigments these are much more intense effect coatings and have a more vibrant effect. 41

42 Pearlescent pigments give a coating that shiny appearance. Tiny reflective metal or refractive mica pigments are added to the coating to reflect light in a special way. Use of a pearlescent coating can be a great way to differentiate an architectural project. Special Effects Pigments Color-Shifting Pearlescent In contrast, color-shifting pigments are added so that the color will shift when viewed from different angles or sunlight. A combination of pearlescent mica and aluminum flakes are used. Maybe you have seen an automobile with color-shifting paint on it. That s the first industry that began using colorshifting pigments in a big way. As the car is coming toward you, it looks like one color. When it gets to you, it s another color and as it is moves away, it changes to yet another color. Color-shifting pigments can be used for a more subtle or dramatic effect depending on what you are looking to achieve with your project. 42

43 Dramatic Color-Shifting This is an example of dramatic color-shifting in a coating. The homeowner of this California residence wanted the home to fit with nature. The color of the home changes with the natural rhythm of the sun throughout the day. The color-shifting pigments are dramatic in that they take on a yellow and green hue in the morning and turn from silver to a bronze, brick or dark brown color in the evening. This special effect is available in coil and extrusion coatings. California Residence, Woodland, CA 43

44 This is the Welcome Center at Port Canaveral, Florida, which uses color shifting pigments in a more subtle way. With this shimmering, iridescent exterior, its color changes throughout the day and at different angles. More Subtle Color-Shifting Exploration Tower at Port Canaveral, Florida 44

45 There are dozens of examples of how you can use a coating to achieve a specific look that mimics natural materials without having to pay the cost of the actual materials. For example, you can make: Coatings Mimic Natural Materials Used on metal roofing panels, wall panels, garage doors and other metal surfaces Print coatings can look like burnished slate, aged copper and wood Crinkle finish coatings that provide unique texture reflecting light a metal roof that looks like Terra Cotta garage doors that look like wood a coating that mimics new or aged copper During the print coating process, a print stamp is used to apply the second coat, which is a tinted color. A third coat can even be used depending on the special effect being created. Crinkle finishes are also popular. In the bottom right photo, you can see metal roofing that looks like shingles. These are just a few of the many effects available. 45

46 Looks Like Weathered Steel Here s a college campus building that wanted to have the unique look of Cor-Ten steel without the price. The print coating uses a base color coat and a tint applied with a coil roller that has a pattern similar to a stamp. The tint is applied with the patterned roller to create the final effect print. It s all done with a coating. Central Arizona College, Maricopa Campus 46

47 Eco-Friendly Cool Pigment Technology Solar Reflective coatings: Lower energy costs without sacrificing performance or beauty Keep coating and building cooler Meet LEED and Energy Star requirements Here s an eco-friendly technology you may not have heard of called Cool Pigment Technology. The more that you can reflect solar energy from the surface of a metal roof or building, the less energy needed to cool the building. Occupants are more comfortable and building owners save on energy cooling costs. Both the metal roof and metal walls of a building can have Solar-Reflective coatings. Depending on the color of the coating, the pigments in these coatings have different levels of solar reflectance that s what the numbers represent. Of course, white has the highest reflectivity, but you can select from a wide range of colors and still achieve the cooling effect needed to meet LEED and Energy Star specifications. Standard.67 Cool.72 Standard.47 Cool.56 Standard.21 Cool.33 Standard.25 Cool.30 Standard.14 Cool.28 Standard.11 Cool.28 Standard.08 Cool.26 47

48 This simple diagram shows the sun hitting the roof and the Solar Reflective pigments deflecting this thermal energy back to the atmosphere. Solar Reflective Pigments As you ve seen, a lot can be done in a coating with different types of pigments. 48

49 Purpose of Resins Bind paint components together Primary source for a coating s durability and physical properties Next, we re moving onto the resin system of a coating. The primary function of resin is to act as the binder in a paint formulation by binding all of the components together and to achieve solid coating adhesion to the substrate. It is the source for a coating s durability and physical properties. It increases the physical strength and chemical resistance of the coating film, and allows for the curing process to occur while paint is drying. 49

50 There are many options available for resins today as you can see by this detailed list. I won t go through them all in detail, but this gives you a good idea of the chemistry involved in a coating. Common Resin Systems Fluoropolymer (PVDF) Silicone Modified Polyester (SMP) Polyester FEVE Vinyl Plastisol PVC Acrylic Polyurethane 50

51 The industry is driven by good, better and best categories of resin. Resin Performance Each resin type offers different outdoor durability performance characteristics. GOOD Polyester Generic polymer system with limited weather performance; can achieve wide variety of colors because of the organic pigments used. BETTER SMP Provides harder surface, color retention and weather resistance of fluoropolymer coatings. FEVE Provides harder surface and high gloss level not seen with PVDFs. BEST 70% PVDF Current stateof-the-art coating. Carbon/fluorine bond is one of strongest chemical bonds known. Nonsticky finish enables pollutants to wash away. On the left, you see the Good resin category. This consists mainly of polyester coatings with a few acrylic resins designed for nonmonumental use in the residential space on low-rise structures. In the Better section of the slide depicted in red, we get into the better category of resins. There are some acrylics and 50% PDVF product. PDVF is an acronym for the resin, which is polyvinylidene chloride. A lot of this is high-end residential, light commercial, and lowrise construction such as strip mall centers. Now onto the Best category on the right, you have both FEVE and 70% PVDF resins in your coating system. FEVE delivers a harder surface and higher gloss level, while the 70% PVDF form some of the strongest chemical bonds known these are the best coatings on the market today. Again, three different resin quality categories depending on the need. It s best to consult with a coatings manufacturer on your specific project needs. 51

52 Resin Comparison This chart contains a lot of useful data. You can see on the far left that we ve listed the coating qualities. Then, in the Good, Better and Best columns, we show how these coatings perform. You can see how important it is to understand the end use for the coating before selecting the right formulation for your project needs. GOOD BETTER BEST Resin Type Polyester Silicone Modified Polyester 70% PVDF Chalk Good Very Good Excellent Fade Good Very Good Excellent Weathering Good Very Good Excellent Film Integrity 5-20 years years years Gloss Retention Good Very Good Excellent Dirt Resistance Poor Very Good Excellent Pigments/Color Organic Organic/Inorganic Inorganic End Uses Interior: home appliance, lighting fixtures, wall panels Exterior: metal building components, agricultural, corrugated panels Exterior: metal building components, monumental buildings 52

53 Next, we re moving onto solvents. This is the third main ingredient in coatings. Solvents are used to promote good application properties as well as to thin the paint, controlling viscosity, flow and leveling. Purpose of Solvents Mainly used as thinner (diluent) to help maintain and control paint viscosity Chosen for compatibility with the paint system Solvent types vary in: Evaporation rate Ability to disperse in solids Ability to help film coalesce Scientists choose the solvent based on compatibility with the different resins they are using in the coating. Evaporation rate can vary by solvent. So does its ability to disperse the solids in the resin, and the ability to help the film coalesce or form a uniform film. During the oven bake, as solvents are coming out of that wet film, you want them to come out at a certain rate so that the resin and the pigments have time to intermingle and form a good, uniform film so that any spot you might check on the coated substrate would be very representative of any other spot on the coating film. It would be totally homogeneous across the whole coated substrate. 53

54 We ve just completed learning objective three identifying coating components and their role in the coating system. COMPLETED: Learning Objective Three Identify coating components and their role in the coating system. 54

55 Let s move on to objective four I ll tell you a bit more about the coating manufacturing process and coating chemistry. Learning Objective Four Describe the coating manufacturing process and coating chemistry. HS UI GP H E RP IEO R F OP ER RM FA ON RC ME A NR C E H AI TR EC CH TI UT ER CA TL UC RO A L T CI NO GA ST I N G S 55

56 Coating Manufacturing Process Creating a coating formulation to meet customer s exact needs Dispersing precise amounts of each material is imperative Creating a coating formulation that meets the customer s exact needs for color, performance, gloss, sheen, hardness, film thickness and other characteristics is both an art and science. Once the perfect formulation is designed by lab chemists for an exact color match, that color has to be produced in bulk quantity by the coating manufacturing facility. The manufacturing process is a series of combining raw materials using specific processing instructions. The bottom photo shows automated dispensing equipment used in the industry to combine materials. Computers store the formulations and precisely dispense each ingredient. A complex maze of pipes is connected to ingredients to deliver the precise amount to the coating mixing tanks. There are some manual adds, which is depicted by the photo in the upper right a factory operator transferring resin or solvent out of a drum that is probably bounded and grounded to a mixing vessel. HS UI GP H E RP IEO R F OP ER RM FA ON RC ME A NR C E H AI TR EC CH TI UT ER CA TL UC RO A L T CI NO GA ST I N G S 56

57 Precise Color-Matching Process To assure consistent formulation batch-tobatch, computer used to dispense precise amount of each ingredient Critical to disperse pigments adequately in resins and solvents HS UI GP H E RP IEO R F OP ER RM FA ON RC ME A NR C E H AI TR EC CH TI UT ER CA TL UC RO A L T CI NO GA ST I N G S During the manufacturing process, part of the formulation is centered around color-matching. Most adjustments are done when you mix the materials into the coatings batch. You dispense the materials and then you mix them. It s critical that they are all mixed and uniform. Then, the coating goes through a series of color and solvent adjustments. A lot of the way this mixing process works is very similar to making a recipe; you put all the ingredients together, and then mix those and make sure they re processed the way they re designed to be processed. Sometimes, it can take months or even years to complete a large architectural project. The coating needs to match on the entire building when the project is complete, even if it was installed over an extended period of time. For retail stores and restaurant chains, colors need to match store after store to maintain the brand integrity. That s why coating manufacturers need to perfect colormatching batch after batch. That s a brief look at the coating manufacturing process and the science behind it. 57

58 Typical Coating Application Paint Coat 0.8 MILS Primer 0.25 MILS Substrate (Metallic Coating) Chemical Conversion Treatment HS UI GP H E RP IEO R F OP ER RM FA ON RC ME A NR C E H AI TR EC CH TI UT ER CA TL UC RO A L T CI NO GA ST I N G S Pigment Particles Resin This drawing helps you understand how the coating works to provide protection of the substrate. This image shows a cross-section of the coating. Starting at the bottom, the gray layer demonstrates the metallic substrate. On top of that is the pretreatment chemical conversion coating. This is applied to the metal to protect against corrosion and to make it easier for the coating to adhere. Next, you ll notice there is.25 mils of primer, which you see in yellow. Primer is an important base coat that allows the finishing paint to adhere much better. It forms a binding layer that is ready to receive the color paint. The primer binds the top coat to the substrate to provide additional anti-corrosion protection. The topcoat depicted in this image is white with green flecks representing the resin and pigment particles embedded within that resin system. The topcoat is a combination of resin, pigment and other ingredients. It is typically applied in two coats. This paint coat layer is up to 0.8 mils thick. There is a lot of innovation that goes into high-performance coatings to make them so thin yet perform so well. 58

59 It s hard to believe that all of the layers of architectural coatings are thinner than a strand of hair, yet they can stand up to very harsh environments including wind, rain and sun. Did You Know? Architectural coatings are thinner than a strand of hair, yet stand up to the wind, rain and blazing sun. Average Thickness of Human Hair ~100 microns Source: HS UI GP H E RP IEO R F OP ER RM FA ON RC ME A NR C E H AI TR EC CH TI UT ER CA TL UC RO A L T CI NO GA ST I N G S 59

60 We ve just completed objective four where I ve described the manufacturing process and chemistry of coatings in a bit more detail. COMPLETED: Learning Objective Four Describe the coating manufacturing process and coating chemistry. HS UI GP H E RP IEO R F OP ER RM FA ON RC ME A NR C E H AI TR EC CH TI UT ER CA TL UC RO A L T CI NO GA ST I N G S 60

61 Let s move onto our fifth learning objective, which is identifying industry standards related to performance for coatings. Learning Objective Five Identify industry standards relative to the performance requirements of coatings for metal building components. 61

62 Precise color matching is critical. We refer to it as the L-A-B method. Measuring Color Measured in three dimensions using standard: L axis measures light to dark (white to black) a axis goes from red to green b axis goes from yellow to blue E = square root of Delta L squared + Delta a squared + Delta b squared from a sample to the standard The D-L value concerns just the lightnessdarkness, and it s represented by the vertical axis on the diagram. As you go on the plus side of the 3-dimensional chart, the color becomes lighter or whiter and as you go on the minus side of that chart, it becomes darker or blacker. The D-a or Delta A scale is the redness/greenness chart. As you move along that chart, the positive side is red, and the negative side of the chart is green. Likewise, the third dimension is blue and yellow, which is the Delta B scale. It goes from yellow on the positive side to blue on the negative side. We use this method to zero in on color. When you measure color, you want to try and get to the center of this 3-dimensional chart so everything is as close to zero as possible. That s almost an exact color match. This type of color measurement is critical when matching color to an exact specification or brand. For example, Ikea blue or Target red. 62

63 Testing and Coating Performance Factors such as: Exposure to sun (UV light) Moisture and humidity High temperatures Temperature fluctuations Lead to: Color changes Chalking Fading Understanding weather impact on painted metal helps manufacturers develop products to meet specific performance requirements. We look at a lot of different factors. We look at UV exposure and how that might affect the coating performance Moisture and humidity, high temperature and temperature fluctuations freeze/thaw cycles. One or any of these can lead to color changes, chalking and fading. Understanding the impact of weather helps manufacturers deliver products that will perform best based on the location and environment. 63

64 Rigorous Weather Testing Two key testing approaches Natural exposure to outdoor elements Accelerated testing There are a couple of key types of weather testing that are done. The most important and accurate is natural exposure to the elements, which you can see in the photo on the left. This is done at specialty labs in warm climates like Florida, where panels are exposed to high humidity, heat and salt spray sometimes for decades. This data is crucial to help scientists continue to innovate and improve the performance of coatings. Coating manufacturers want to have an idea of how well a coating is going to perform once they put it into the market. This helps them develop real-world products that will perform year after year, retaining their color AND quality for a lasting impression. The second kind of testing is accelerated indoor testing, which you see in the photo on the right. These machines use salt spray, humidity and heat. This testing is most useful in the development stages of coatings to test various ingredients when formulating to see which ones will be the best choice for a particular coating. 64

65 In addition to exposure testing, physical tests are performed to gauge a coating s performance. Physical test components are mainly driven by ASTM methods, which is the American Society for Testing and Materials. Physical Tests ASTM test methods measure: Color retention Film thickness and hardness Gloss levels Resistance to solvents Flexibility We look at a variety of factors, such as color retention using a color instrument. We can read a reference standard and read the coated substrate in the field to see exactly how much it s changed. We can look at film-thickness to ensure the coating will properly cover the substrate and offer protection from corrosion. We also have instruments that can read gloss levels. For example, there s a big difference between a matte finish and a medium gloss. Resistance to solvents. The basic test for doing that is taking solvent samples and rubbing the coating substrate to see how well the coating fares. That tells us to a degree if the coating will be resistant to certain cleaning methods used. And finally, flexibility. There are tools in the laboratory to look at the coated substrate on the post-fabricated part for flexibility properties like adhesion and cracking. 65

66 We ve completed learning objective five, looking at different industry test methods related to coating performance requirements. COMPLETED: Learning Objective Five Identify industry standards relative to the performance requirements of coatings for metal building components. 66

67 Wrapping things up, we ve covered five learning objectives today. Course Learning Objectives 1. Identify advantages of building with metal. 2. Provide overview of the coil coating process and the benefits of pre-paint. 3. Identify coatings components and their role in the coating system. 4. Describe coating manufacturing process and coating chemistry. 5. Identify industry standards relative to the performance requirements of coatings for metal building components. First, we talked about the advantages of building with metal. Then, we described the coil coating process and the benefits of prepaint. After that, we discussed the components of coatings and their role in the coating system. From there, we moved into the coating manufacturing process and coating chemistry. Then, we looked at industry standards related to performance requirements. 67

68 Thanks for joining us today! We hope you found this course valuable. You can learn more about Valspar by visiting our website: valsparinspireme.com Or, you can contact us at Contact Information Robyn Ommen 68

69 This presentation is protected by copyright laws. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to constitute approval, sponsorship or endorsement by the AIA of any method, product, service, enterprise or organization. The statements expressed by speakers, panelists, and other participants reflect their own views and do not necessarily reflect the views or positions of The American Institute of Architects, or of AIA components, or those of their respective officers, directors, members, employees, or other organizations, groups or individuals associated with them. Questions related to specific products and services may be addressed at the conclusion of this presentation. 69