{"id":2862,"date":"2015-08-07T08:00:36","date_gmt":"2015-08-07T14:00:36","guid":{"rendered":"https:\/\/www.ulprospector.com\/knowledge\/?p=2862"},"modified":"2023-06-06T12:57:33","modified_gmt":"2023-06-06T18:57:33","slug":"pc-coil-coating-explained","status":"publish","type":"post","link":"https:\/\/ulprospector.ul.com\/2862\/pc-coil-coating-explained\/","title":{"rendered":"Coil Coating Explained"},"content":{"rendered":"

\"coil1\"Over 800 million tons of coil-coated<\/a> metal are produced and shipped annually in North America alone. Coil coating (see Diagram I) is a very efficient way to produce a uniform, high quality, coated finish over metal in a continuous automated fashion. Coil coating is also referred to as pre-painted metal, because the metal is painted prior to, rather than after, fabrication.<\/p>\n

In the coil coating process, the metal coil is first unwound, cleaned and pre-treated, applied on a flat continuous sheet, heat cured, cooled and rewound for shipment. At the fabricator, it is then cut to the desired size and formed into its finished shape. Versus most other application methods, coil coating efficiency is nearly 100%. Application is at very high line speeds as modern coil lines can run at speeds as high as 700 feet per minute and cure the applied paint in 15 – 45 seconds. As opposed to a spray-applied coating, for example, a coil-coated, formed surface offers uniform film thickness rather than the thicker films on edges, corners and bends that is more typical of spray-applied coatings.<\/p>\n

\"Click<\/a>
Diagram I – Typical Coil Coating Line. Click to view source.<\/figcaption><\/figure>\n

<\/a>Topcoats are applied by reverse roll coat in which the applicator roll travels in the reverse direction of the strip and thus provides a smoother film with fewer defects. Primers<\/a> and backers are normally applied by direct roll coating. Some lines also apply coil coatings using an extruder or via a solid block of paint with a softening point such that it can be applied smoothly when heated.<\/p>\n

\"Table
Table I \u2013 Synopsis of Coil Coating Options and Benefits<\/figcaption><\/figure>\n
\"Schematic
Schematic I – Coil Coated Substrate<\/figcaption><\/figure>\n

The types of paint curing employed in the coil industry include thermal, infrared, induction and UV cure. By and large, the vast majority of coil coatings are cured using gas-fired ovens. Accordingly, the remaining portions of this article will focus on thermal-cured coil coatings. Coil primers and backers are normally applied much thinner than spray-applied liquid or powder coatings<\/a>, dip<\/a> or electrocoat paints. Applied primer dry film thicknesses are normally in the range of 4 \u2013 6 microns in thickness, whereas topcoats are normally applied to provide a dry film thickness of 18 \u2013 20 microns.<\/p>\n

Special consideration when formulating coil coatings include adjustments in the resin technology, crosslinking, solvent system, catalyst<\/a>, surface modifiers<\/a> and lubricants<\/a> to accommodate proper cure, flow and leveling, and minimization of surface defects. Once cured, coil coatings can offer excellent handling, physical, chemical and environmental properties. From a paint usage standpoint, polyesters<\/a> make up the bulk of coil coatings. Table II details typical materials utilized in a polyester coil coating.<\/p>\n

\"Table
Table II \u2013 Typical Raw Materials (on Resin Solids) used in a Typical Polyester Coil Topcoat (1.2:1.0 Pigment:Binder, Dupont R960 Titanium Dioxide)<\/figcaption><\/figure>\n

In summary, coil coating technology has grown more rapidly than more conventional application technologies due to a variety of benefits that include cost savings, versatility, environmental, performance and quality issues.<\/p>\n","protected":false},"excerpt":{"rendered":"

Over 800 million tons of coil-coated metal are produced and shipped annually in North America alone. Coil coating (see Diagram I) is a very efficient way to produce a uniform, high quality, coated finish over metal in a continuous automated … Continued<\/a><\/p>\n","protected":false},"author":12,"featured_media":2884,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_monsterinsights_skip_tracking":false,"_monsterinsights_sitenote_active":false,"_monsterinsights_sitenote_note":"","_monsterinsights_sitenote_category":0,"episode_type":"","audio_file":"","podmotor_file_id":"","podmotor_episode_id":"","cover_image":"","cover_image_id":"","duration":"","filesize":"","filesize_raw":"","date_recorded":"","explicit":"","block":"","itunes_episode_number":"","itunes_title":"","itunes_season_number":"","itunes_episode_type":"","footnotes":""},"categories":[16],"tags":[],"ppma_author":[1249],"class_list":{"0":"post-2862","1":"post","2":"type-post","3":"status-publish","4":"format-standard","5":"has-post-thumbnail","7":"category-paint-coatings","8":"entry"},"yoast_head":"\nCoil Coating Explained | Prospector<\/title>\n<meta name=\"description\" content=\"Coil coating is a very efficient way to produce a uniform, high quality coated finish over metal. 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Lewarchik, President and CEO of Chemical Dynamics, LLC, brings 40 years of paint and coatings industry expertise to his role as a contributing author with the Prospector Knowledge Center. As a contributing writer, Ron pens articles on topics relevant to formulators in the coatings industry. He also serves as a consultant for the Prospector materials search engine, advising on issues related to optimization and organization materials within the database. Ron's company, Chemical Dynamics, LLC (www.chemicaldynamics.net), is a full-service paint and coatings firm specializing in consulting and product development based in Plymouth, Michigan. Since 2004, he has provided consulting, product development, contract research, feasibility studies, failure mode analysis and more for a wide range of clients, as well as their suppliers, customers and coaters. He has also served as an Adjunct Research Professor at the Coatings Research Institute of Eastern Michigan University. As such, Ron was awarded a sub-grant from the Department of Energy to develop energy-saving coating technology for architectural applications, as well as grants from private industry to develop low energy cure, low VOC compliant coatings. He taught courses on color and application of automotive top coats, cathodic electro-coat and surface treatment. His experience includes coatings for automotive, coil, architectural, industrial and product finishing. Previously, Ron was the Vice President of Industrial Research and Technology, as well as the Global Director of Coil Coating Technology for BASF (Morton International). During his fourteen-year tenure with the company, he developed innovative coil coating commercial products primarily for roofing, residential, commercial and industrial building, as well as industrial and automotive applications. He was awarded fifteen patents for new resin and coating formulas. From 1974 to 1990, Ron held positions with Desoto, Inc. and PPG Industries. He was the winner of two R&D awards for coatings utilizing PVDF resins, developed the first commercial high solids automotive topcoat and was awarded 39 U.S. patents for a variety of novel technologies he developed. He holds a Masters in Physical Organic Chemistry from the University of Pittsburgh and subsequently studied Polymer Science at Carnegie Mellon University. Ron lives in Brighton, Michigan with his family. Contact Ron via email\u00a0or through his company\u2019s web site at www.chemicaldynamics.net to learn more about his consulting services\u2026\",\"sameAs\":[\"https:\\\/\\\/ulprospector.ul.com\"],\"url\":\"https:\\\/\\\/ulprospector.ul.com\\\/author\\\/ron-lewarchik\\\/\"}]}<\/script>\n<!-- \/ Yoast SEO plugin. -->","yoast_head_json":{"title":"Coil Coating Explained | Prospector","description":"Coil coating is a very efficient way to produce a uniform, high quality coated finish over metal. 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Lewarchik, President and CEO of Chemical Dynamics, LLC, brings 40 years of paint and coatings industry expertise to his role as a contributing author with the Prospector Knowledge Center. As a contributing writer, Ron pens articles on topics relevant to formulators in the coatings industry. He also serves as a consultant for the Prospector materials search engine, advising on issues related to optimization and organization materials within the database. Ron's company, Chemical Dynamics, LLC (www.chemicaldynamics.net), is a full-service paint and coatings firm specializing in consulting and product development based in Plymouth, Michigan. Since 2004, he has provided consulting, product development, contract research, feasibility studies, failure mode analysis and more for a wide range of clients, as well as their suppliers, customers and coaters. He has also served as an Adjunct Research Professor at the Coatings Research Institute of Eastern Michigan University. As such, Ron was awarded a sub-grant from the Department of Energy to develop energy-saving coating technology for architectural applications, as well as grants from private industry to develop low energy cure, low VOC compliant coatings. He taught courses on color and application of automotive top coats, cathodic electro-coat and surface treatment. His experience includes coatings for automotive, coil, architectural, industrial and product finishing. Previously, Ron was the Vice President of Industrial Research and Technology, as well as the Global Director of Coil Coating Technology for BASF (Morton International). During his fourteen-year tenure with the company, he developed innovative coil coating commercial products primarily for roofing, residential, commercial and industrial building, as well as industrial and automotive applications. He was awarded fifteen patents for new resin and coating formulas. From 1974 to 1990, Ron held positions with Desoto, Inc. and PPG Industries. 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