Overview of Coil Coatings Technology
Coil covering, also known as pre-painted steel or pre-coated steel, refer to a technology where various protective and decorative surface treatments are applied to steel sheets during continuous coil production. The steel coils enter a Coil Coatings line where they undergo a multi-stage pretreatment and application process to produce coated coils ready for forming and fabrication. Various resins and pigments are used depending on the end-use requirements to provide corrosion protection, durability, aesthetics and functional properties to the coated steel substrates.
Pretreatment Process
The pretreatment process is a critical step in ensuring excellent adhesion between the steel substrate and the coating system. During pretreatment, the steel coils are first degreased and cleaned to remove any surface contaminants. They then undergo chemical treatment where the steel surface is chemically converted to produce a layer promoting coating adhesion. Common pretreatment chemistries involve phosphating, chromating or rare earth based systems that react with the steel surface. This is followed by a rinse stage to remove any residues before application of the primer layer. The pretreated steel thus provides an activated, corrosion resistant substrate for coating application.
Coil Coatings Technologies
There are different technologies used for applying primers, paints and backers to the pretreated steel coils during continuous coil coating operations. Roll coating involves passing the steel coil through a series of rollers, one of which is flooded with the coating composition. This leaves a thin, uniform wet film on the steel surface which is then cured either through infrared radiation or by hot air impingement. Another method is hot-melt extrusion where powder coating compositions are melted and extruded through a die onto the moving steel substrate followed by curing. Liquid coatings are also applied through slot-die coating technology which deposits precise amounts of liquid onto the steel in a continuous process.
Coating Product Types
Depending on end-use requirements, a variety of coating systems and products have been developed for pre-coating steel sheets. Single layer primers or topcoats are used where only corrosion protection or functional properties are needed. Two-coat systems with a primer and a topcoat provide both corrosion protection and aesthetics. In three-coat systems, an adhesive backing coat is applied in addition to improve formability during post-coating fabrication. Specialty coatings are used as well such as roofing, metallic and plastisol coatings tailored for specific applications like architectural wall and roof panels. Coated prepaints are also available which require over-painting with liquid topcoats for enhanced aesthetics and protection.
End-use Applications
Some key where coil coated steel finds applications include:
1. Construction Sector - Coil coated steel is widely used in construction of roofing, walling, fencing, doors and other exterior construction elements. Its durable coating maintains the aesthetic looks and provides robust corrosion resistance needed in harsh building exteriors.
2. Transportation - Automotive panels, fleet vehicles, RVs, cargo containers amongst others utilize pre-coated steel sheets for their durable, scratch and corrosion resistant properties enhancing product lifespan.
3. Appliances - Domestic appliances from refrigerators to washing machines commonly employ prepainted steel for its formability and maintenance of an attractive outer finish through the product useful life.
4. Signage - Directional and brand signage frequently employ coil coated aluminum or steel composite panels known for their weather resistant qualities maintaining visibility and branding impact over many years.
5. Furniture - Office furnishing, outdoor and playground equipment take advantage of coil coated steel attributes like formability, design flexibility and prolonged corrosion protection in diverse usage environments.
Benefits of Coil covering
Some key advantages offered by coil coating steel sheets include versatility, design freedom, corrosion resistance, durability, consistency and cost effectiveness compared to field-painting. Robust pre-treatments and modern coating technologies ensure long-lasting aesthetics and protection even in demanding applications and locations. The continuous process enables mass production of coated coils to tight specifications eliminating inconsistencies of field painting. This seamlessly integrates pre-painted steel into diverse manufacturing operations as the preferred material for varied durable end products and constructions.
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