Coil coating is a highly sustainable and highly automated industrial process for efficiently coating metal rolls. Because the metals are treated before they are cut and shaped, the entire surface is cleaned and treated, providing a closely bonded solution. (The formed part can have many holes, hidden areas, valleys, and hidden areas that make it difficult to clean and evenly paint.) Coated metal coils (often called finished metal) are often considered more durable and more corrosion resistant than most pegs painted metal.
Each year, 4.5 million tons of coils and aluminum coils are manufactured and shipped in North America, and 5 million tons in Europe. In almost every five-year period since the early 1980s, the growth rates of coated metal coils have exceeded the growth rates of both steel and/or aluminum production.
Video Coil coating
Process
The definition of coating coating process according to EN 10169: 2010 is' the process in which the coating material (organic) is applied to a rolled metal strip in a continuous process which includes cleaning, if necessary, and an initial chemical treatment of the metal. surfaces and either one side or two sides, one or several applications of paint (liquid) or powder coatings which are then cured or/and laminated with a permanent plastic film '.
Metal substrate (steel or aluminum) is sent in the form of coils from the rolling mill. Coil weights vary from 5-6 tons for aluminum and about 25 tons for steel. The coils are positioned at the beginning of the line, then canceled at a constant speed, through various pre-treatment and coating processes before being pulled back. Two strip accumulators at the beginning and end of the line allow the work to be continuous, allowing the new coils to be added (and the coils finished removed) by the process of metal stitching without having to slow or stop the line.
Maps Coil coating
Coil coating lines
The continuous process applies up to three separate layers of coating to one or both sides of the metal strip substrate taking place on the coil coating line. These lines vary greatly in size, with widths from 18 inches to over 60 inches and speeds from 100 feet per minute to 700 feet per minute; However, all coil-coating lines share the same basic process steps.
Typical organic coil coating lines consist of decoilers, inlet accumulators, cleaning, chemical pretreatment, primary layer applications, curing, final coating applications, curing, exit accumulators and recoilers.
The following steps take place on modern coating lines:
- Mechanical stitches from strip to predecessor
- Clear strips
- Power brushing
- Treatment of surfaces with chemical conversion
- Dry out the bar
- Primary apps on one or both sides
- Section via first preservation oven (between 15 and 60 seconds)
- Cool strip
- Overlays on one or both sides
- Section via second preservation oven (between 15 and 60 seconds)
- Cool to room temperature
- Roll up the layered coil
Layers
Available coatings include polyester, plastisol, polyurethane, polyvinylidene fluoride (PVDF), epoxies, primers, backing layers and laminated films. For each product, layers are built in a number of layers.
The Primary layer forms an important link between pretreatment and the final layer. Basically, a primer is needed to provide an inter-coat attachment between pretreatment and the final layer and is also necessary to improve corrosion resistance in the total system. The primary composition will vary depending on the type of final coating used. Primer requires compatibility with various pretreatment and paint top coat systems; therefore, they usually consist of a mixture of resin systems to achieve this goal.
Backing coat is applied to the bottom of the strip with or without a primer. Layers are generally not as thick as a coating layer used for exterior applications. Backing coats are generally not exposed to corrosive environments and are not visible in the final application.
Apps
Prepainted metal is used in various products. These can be formed for many different applications, including those with T bends, without loss of coating quality. Major industries use prefabricated metal in products such as building panels, metal roof wall panels, garage doors, office furniture (desks, cube dividers, file cabinets, and modular cabinets), housewares (refrigerator, machine dishwasher, freezer, range hood, microwave). ovens and washing machines and dryers), outdoor panels heating and air conditioning and require ducts, commercial equipment, vending machines, food service equipment and cooking cans, beverage cans, and automotive panels and parts (fuel tanks, body panels , bumper), The list continues to grow, with new industries shifting from the post-painted process to the preparation process each year.
Some high-tech and complex coatings are applied by coil coating process. Coatings for cool metal roofing materials, smoke-eating building panels, antimicrobial products, anti-corrosive metal components, and solar panels use this process. Pretreatments and coatings can be applied by coil coating process with a very precise, thin, uniform layer, and make some complex layers feasible and more cost-effective.
The largest market for ready-made metals is in commercial and residential construction. These are selected for quality, low cost, design flexibility, and properties that are beneficial to the environment. Using prepainted metals may contribute to credit towards LEED certification for sustainable design. A variety of color options are available with pre-prepared metal, including bright colors for modern design, and natural finishes and weather in rural expressions. Prepainted metal can also be formed, almost like plastic, in liquid form. This flexibility allows architects to achieve a unique and expressive design using metal.
History
In the past traditional manufacturing, steel and other metals arrived at factories in untreated and unpainted conditions. Companies will fabricate and paint or treat metal components of their products before assembling. It's expensive, time consuming, and harmful to the environment. The coil coating process was pioneered in the 1930s for the painting, coating, and large metal coils before they arrived at the manufacturing facility. The venetian blind industry is the first to use pre-painted metal.
References
- http://www.coilcoating.org
- http://www.prepaintedmetal.eu
- http://www.prepaintedmetalacademy.eu
- http://www.creativebuilding.eu
- http://www.creativeroofing.eu
- http://www.thefabricator.com/article/coilprocessing/what-you-should-know-about-stamping-coated-coil
- http://www.euramax.eu
Source of the article : Wikipedia
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