Understanding Pre-Painted Metal
Understanding Pre-Painted Metal
Understanding Pre-Painted Metal
Pre-Painted Metal
Michelle Vondran
Technical Manager
Steelscape
CONTINUING EDUCATION
2. Specify the three common types of paint systems, their differences and appropriate
applications.
3. Describe the enhancement options available for pre-painted metal and how they can be
modified specific to project needs.
4. Identify pre-painted metal durability issues, their causes and applicable warranty
considerations for end building users.
Presentation Overview
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What Is Pre-Painted Metal?
Pre-painted metal reflects rolls of steel or aluminum in which paint
is baked on.
The term pre-painted arises from the metal being painted prior to
being formed or shaped into its finished state.
A) Air-Brush
B) Dipping
C) Rolling
D) Brushing
Spotlight Question
How is paint applied to metal for the
majority of building applications?
A) Air-Brush
B) Dipping
C) Rolling
D) Brushing
Application of Paint to Metal
• Pre-painting (coil coating) is a method
of applying paint to metal
• In a continuous process, the metal is
first cleaned before coatings are
applied using rollers
• Following coating, paint is baked on
• Painted metal is produced at speeds
around 100 feet per minute and up (up
to 700 fpm)
• The curing process takes only 15-30
seconds
Source: NCCA
Advantages of Coil Coating
• Surface cleaned and treated prior to painting
enabling a tightly bonded finish
• Paint applied in a controlled and autonomous
environment enabling high consistency
• Efficient use of paint—A typical paint system is 1.4
mils thick, which includes the backer and primer
(Top coat 0.7-1.0 mils)
• By comparison most industrial coatings are 2-5
mils thick
• As metal is painted before fabrication, coating
must be hard, durable, and flexible
• Closed loop system—Curing ovens capture and
burn harmful VOCs Source: PPG Industries
Limitations of Coil Coating
• Process is rapid once running, but can
involve significant set up based on
properties of paint system
• Process is based on efficiencies of
scale, resulting in coaters having large
minimum orders for finished product:
• Can constrict the color palette
• Make it difficult, expensive, or
extend lead times on custom
colors
Quality Control in Coil Coating
• Tests for suitability:
• T bend test
• To simulate forming and test for cracking
• Reverse impact test
• Stress test to identify if adhesion is lost
• Color validation and consistency across strip to
standard
• Gloss validation and consistency across strip to
standard
• Film thickness—critical for long term
performance
Source: NCCA
Typical Layers of Painted Steel
• Backers – Provide color, some
protection and a basis for adhesives
Clear Coat
• Primer – Prepare the substrate for
painting by providing ‘bite’
• Metallic coating – Corrosion resistance Top Coat
• Pre-Treatment – Paint adhesion Primer
• Top coats – Protection from outside Pre-Treatment
elements, color, and aesthetic Metallic
Metal
appearance Coating
• Clear coat (optional) – Added Primer
protection and color depth Backer
Metallic Coating
• Galvanizing and aluminum-zinc alloys are the
most widely used metallic coating for the
corrosion protection of steel
• Hot dipped galvanizing adds a coating of 100%
zinc
• Galvalume and ZINCALUME are two common
trade names for 55% Al-Zn
• Aluminum offers enhanced corrosion
protection
• 55% is the optimal ratio – any difference
to this will not be a Gavalume product
Metallic Coating
• Aluminum is inert and provides a protective
rather than sacrificial barrier
• The aluminum component (55%) of Al-Zn
provides corrosion protection and corrosion
warranty, while the zinc component (45%)
provides the sacrificial characteristic that
protects material edges and cuts
• BIEC-licensed metallic coaters of Al-Zn provide
a corrosion warranty (20-25 year on average)
• Installation environment considerations can
influence metallic coating choice
What is Paint?
• A liquid designed for application to a
surface in a thin film that cures to a
solid film
• Two important attributes:
• Protection of the surface
• Creation of the desired aesthetic
• Methods for application include
brushing, dipping, spraying, vacuum
coating, rolling
Primary Components of Paint
• Primary components are resins,
pigments, solvents, and additives.
• Resins – The binder of the paint,
determines physical and chemical
properties
• Pigments – Impart color to paint
• Solvents – Dissolve resin to a
consistency suitable for
application
• Additives – Fine tune or improve
performance characteristics
Summary Components of Paint
Resin Pigment Solvent
Physical Properties Aesthetics Application
Component Durability Color Viscosity
Properties Hardness Hiding Levelling
Flexibility Corrosion Resistance Flow
Adhesion Film Strength Stability
Gloss Water Resistance Film Control
Chemical Resistance Solvent Popping
Corrosion Resistance Compatibility
Humidity Resistance
Abrasion Resistance
Impact Resistance
Heat Resistance
Stain Resistance
30% Solvents
30% Resins
Source: PPG Industries
by weight
How is the Right Paint Selected?
• The right balance of resins, SOFT FLEXIBLE HARD BRITTLE
pigments, solvents, and
additives
• Application process to
ensure the right adhesion,
the right color and the right Flexibility Hardness Value Gloss Retention
gloss Thermal Cycle
of a Typical Paint
Mar Resistance
• End use requirements, Resistance
Brittleness
cost, and warranty Impact Resistance
Chipping
Scratches
Cracking
Abrasion Loss
Tensile Strength
Staining
Application Versatile, but typically low Wide range of construction High-end architectural,
exposure applications such as applications including commercial, and high-
agricultural buildings, gutters and residential and commercial profile projects
downspouts, industrial buildings
Other attributes Wide range of colors and gloss Wide range of colors and Excellent chalk and fade
options gloss options resistance and chemical
resistance
AAMA specification 2603 or less / 621 2604 or better / 621 2605 / 621
Paint System Considerations
• Not all polyester systems are the same
• Differential between high-end polyester and
SMP can be marginal
• PVDF still offers the best UV resistance for
optimal exterior durability
• Kynar 500 or Hylar 5000 reflect a trade
name for a PVDF product
• PVDF systems are most durable when it
makes up 70% of the overall resin
composition
Enhancement options for
pre-painted metal
Spotlight Question
What important building considerations
can influence the type of pre-painted
metal specified?
Spotlight Question
What important building considerations
can influence the type of pre-painted
metal specified?
Proximity to salt water
Desired building energy efficiency
Desired color to be used
Visibility of roof surface
Desired reflection of roof surface
Mixed-use materials
Exposed eaves
And more…
Enhancements Overview
• A wide variety of enhancements are
available for pre-painted metal to improve
aesthetics or performance characteristics
including:
• Micas and metallic pigments
• Clear coats
• Marine and industrial enhancements
• Graffiti resistance
• Cool roof pigments
• Texture
• Prints and imagery
Micas and Metallics
Not as noticeable
but the same issue
Extreme Environment Enhancements
• Pre-painted metal systems can be modified
for specific environmental applications
• Includes enhanced durability for coastal or
industrial environments
• Product options include high-build primers
or applying clear coats
• Typically include a three- or four-coat
system with a high build primer
• May enable the creation of a warrantable
finish despite environmental extremes
Clear Coats and Graffiti Resistance
• Clear coat – An additional coating on top of
the paint to provide added protection
• Can provide additional UV fade resistance
• Particularly important for organic
pigments
• Clear coats can also add perceived depth to
a surface or enhanced gloss
• Clear coat protective properties include:
• Added hardness and mar resistance
• Anti-microbial protection
• Graffiti resistance
Clear Coats and Color Variance
• Base colors that have had a clear
coat applied, or are over a thick film
primer, often shift slightly in visual
color
• More apparent on lighter and brighter
colors
• Difference is minor
Source: MBCI
Cool Colors
• ‘Cool’ colors are designed with infrared
reflective pigments Absorption in Near Infrared (NIR)
• Altered chemically and physically to reflect region generates heat
IR wavelengths
• Enables the creation of dark yet ‘cool’ colors
• Any paint system not just high end can be
modified to be ‘cool’
• Minimizes heat build up and reduces
cooling costs in hot climates
Cool Pigments Continued
• How is ‘cool’ defined or measured?
• Solar Reflectance – Amount of solar
radiation reflected off a surface
• Emissivity – The amount of heat a
surface can dissipate away from itself
• Solar Reflectance Index (SRI) – Value
created from solar reflectance and
emissivity with factors such as air flow
considered
• Reviewed by Cool Roof Rating Council
• Unlike other materials, metal’s aged SRI
performance does not deteriorate
SRI values as they may appear on a color chart
Cool Colors and Green Building
LEED v4.1 High Reflectance Roof Guidance
• Look for paints with a high SRI value that
qualify for LEED and ENERGY STAR
programs
• Notably the Heat Island Reduction
credit
• Typically lighter colors will have a higher SRI SRI guidance as it appears in LEED v4.1 BD+C,
value than darker colors, irrespective of SS Credit: Heat Island Reduction
‘cool’ pigment technology Source: USGBC
Light Reflectance Value (LRV)
• Light Reflectance Value (LRV) or glare,
measures the amount of visible or usable
light that reflects from a surface
• LRV is expressed as a percentage from 0 to
100
• Typically, lighter colors will have a higher
value than dark colors
• Texture can impact LRV as well—rough
textures tend to reflect less visible light
Gloss and Sheen
• Gloss and sheen are two other terms used to
describe visible reflection of a surface
• Gloss is the measurement of visible light at
a 60° angle from the surface
• Sheen is measured at 85°
• High gloss/sheen results in high glare or
shine from a surface, while low-gloss/sheen
Difference in gloss and sheen
surfaces have a flat or matte appearance between colors and gloss options.
Source: ASCBP
Textures
Stainless steel lighting fixtures were recessed into the Al/Zn panels creating galvanic corrosion
in an environment in close proximity to salt water.
Incompatible Materials
Painted Al/Zn steel in direct contact with a concrete wall. The steel is corroding under the paint.
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