Architectural Extrusion Market Coatings...extrusion manufacturing process. 2. Identify coatings components and their role in the coating system. 3. Describe coating manufacturing process
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SUPERIOR PERFORMANCE ARCHITECTURAL COATINGS Architectural Extrusion Market Coatings 1 www.valsparinspireme.com
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Architectural Extrusion Market Coatings
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www.valsparinspireme.com
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S U P E R I O R P E R F O R M A N C E A R C H I T E C T U R A L C O A T I N G SS U P E R I O R P E R F O R M A N C E A R C H I T E C T U R A L C O A T I N G S
CEU Credit Course Learning Objectives
1. Identify advantages of the extrusion manufacturing process.2. Identify coatings components and their role in the coating system.3. Describe coating manufacturing process and coating chemistry.4. Identify industry standards relative to the performance
requirements of coatings for metal building components. 5. Understand AAMA specifications and specify the best coating for
a metal building component or project.
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We’ve got 5 learning objectives today: First, I’ll talk a little about the extrusion manufacturing process and the advantages it provides Then, I’ll discuss the components of coatings and how they perform Next, I’ll talk a little about the coating manufacturing process for extruded aluminum products, and coating chemistry The, I’ll provide an overview of the industry standards and tests related to performance We’ll wrap up by discuss the AAMA specifications and how they relate to picking the best coating for your needs I want to remind you to make sure you’ve signed in to get the CEU credit. And we have a feedback form on the table in front of you that we would greatly appreciate you filling out before you leave today. It helps us improve our Lunch ‘N Learn program at Valspar. If you have 5 minutes or so to stay after, I’ll share a little about Valspar’s architectural business and you can look at the color samples that I brought today on the table over there [GESTURE TO THE TABLE].
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Learning Objective OneIdentify advantages of the extrusion manufacturing process.
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Let’s start with the first Learning Objective: identifying the advantages of the extrusion manufacturing process.
S U P E R I O R P E R F O R M A N C E A R C H I T E C T U R A L C O A T I N G SS U P E R I O R P E R F O R M A N C E A R C H I T E C T U R A L C O A T I N G S
Architectural Extrusion Applications Curtain wall Aluminum panels and extrusions Residential and architectural
windows, skylights and door/access systems Louvers and grilles Window trim Entry canopy Soffits, fascia, mullions and
column covers
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Aluminum is commonly used in building materials. It can be shaped into many types of parts. Here are a few examples of extruded building components: curtain walls, aluminum building panels, window trim, soffits, fascia and column covers. These products are used in a lot of different projects…monumental structures, high rise buildings, landmark buildings, hospitals, airports, retail spaces, schools and universities.
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Benefits of Aluminum Extrusion Building Products
Lightweight Stronger Doesn’t expand or contract Recyclable Surface finishes can be coated
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There are many advantages when you use aluminum extrusion products. Aluminum is lightweight. It is stronger because it is one continuous piece of metal. It doesn’t expand or contract when the temperature changes. It is 75 percent recyclable. And of course, aluminum can be coated in a wide range of colors and effects to generate a lot of different finish systems. This provides lots of flexibility for building owners.
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Why Use Aluminum Extrusion Coatings
Coating is required for protection • Prevents aluminum from oxidizing
Many varieties of coatings and finishes • Liquid, Powder, Anodized
Coating selection will depend on:• Aesthetic requirements
• Coating performance needs
• Mar resistance
• Chemical resistance
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All aluminum extrusion products need a coating to protect them against the elements. The coating protects the aluminum from oxidation, which will turn metal to a white color. One of the great aspects of aluminum is that many different coating and finish types can be used. Those coatings can include liquid coatings, powder coatings and an anodized chemical process to keep it from oxidizing. Today, we’ll talk about the liquid coatings process. So how do you select the right coating? There are several considerations. One factor is the look you are trying to achieve—do you have a specific color you are trying to match? Or a specific texture you want to achieve? Another factor is your coating performance. How long do you need the coating to last. Is your project a monumental building where you need the highest quality coating so it will last a long time? Another factor is how chemically resistant you need that coating to be. Is acid rain a problem in the part of the country where the building is being constructed? Will window cleaning solutions be running down the side of the coating regularly? All of these factors affect the decision on which coating is best for the application.
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Aluminum Extrusion Manufacturing Process
Forming aluminum, a malleable material, into shapes of exact specifications • Extrusion presses use high pressure and heat to force aluminum through
the shaped opening of a steel die, creating an extruded aluminum profile
• Can extrude aluminum into a wide variety of shapes
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Let’s take a look at the extrusion manufacturing process. Manufacturers takes a solid block of aluminum, called a billet, and run it through a die to make the shape that is specified for the end product. The extrusion presses use high pressure to force the aluminum through an opening. Aluminum can be shaped into small or large sizes.
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Manufacturing Process Flow
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This is a more detailed diagram of the manufacturing process : The flow runs from left to the right You start with the aluminum billet, which is heated in a furnace to about 850ºF. It comes out red hot and moves into to the extrusion press on a conveyor system. The press can use anywhere from 1,600 to 6,500 tons of pressure to form the aluminum into the required shape. It’s similar to running play-dough through a press. The extruded aluminum comes out on a runout table…it’s still very hot. It’s stretched and cut by a saw to the required length. Then it’s moved by another conveyor belt into what’s called an aging oven. It bakes in the range of 350ºF for 4 to 8 hours to harden. Manufacturers can manipulate the time and temperature to get varying hardness, which is measured in a Rockwell unit. This hardening process develops the mechanical properties of the extrusions, particularly their strength. It sounds like a simple process, but there is a lot of manufacturing design expertise is behind this simple drawing.
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Horizontal Manufacturing Paint Line
Low to medium production Flexible Automatic or manual handguns used to apply liquid paint and
powder coatings
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Let’s move onto the paint process. There are a couple of different types of lines used vertical or horizontal. The first we’re looking at here is the horizontal manufacturing paint line. A couple of facts about using this type of line. It’s very flexible in terms of the product you can coat. Aluminum extrusion curtain walls and aluminum building panels are a couple of examples. It’s a lower to medium production rates in terms of line speed and provides more flexibility. The horizontal line can be designed with varying level of sophistication. The one you see in this illustration is fully automated. The extrusion part is loaded on racks. First, it goes through the Pre-treatment process, which cleans the aluminum, so they get good adhesion during the coating process. Then any remaining moisture is dried off in the oven. Next, there is a series of application booths. The first is the primer coating. There are 2 booths side by side, with spray guns on each side so can be coated on both sides at the same time. Then, the top coat is applied. For the final coat, the part is processed through the clear coat booth if coating system requires it. Then the parts enter a turn-around area, which normally takes 7 to 10 minutes for flashoff…this is where the VOCs are captured in an enclosed area as the coating dries and used to fuel the bake oven. Once the parts are in the bake oven, they remain there for 10 to 12 minutes In the final step, they move along the rack to the unload section of the line.
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Vertical Manufacturing Paint Line
High production, automated Automated system used to apply powder, high solid liquid,
and high performance liquid coatings
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Moving onto the next type of line…the vertical manufacturing paint line. The extrusions are hung vertically rather than horizontally. This type of coating line is not quite as flexible as the horizontal line. It’s designed for high-speed production. The liquid paint system provides the highest throughput possible although powder coatings can also be used. Most vertical lines are used for the residential window and door market. These are lighter weight and smaller extrusion profiles. Similar to the horizontal line in that parts start in the load area, then go to the 5-stage pretreat and through the dryoff oven. The paint booths have disk silos, where the coating application occurs. These silos have reciprocating arms with paint spray shafts or disks mounted in the silos. When the disks spin at 18,000 RPMs, paint is pumped through a tube and dropped through the center part of the unit, which centrifugally atomizes particles. Those particles have a charge and create a fog. The disk rotates, moving up and down and throws the fog in the circle. As the extrusions pass, paint is applied in about 5 strokes. Following that step, parts enter the turnaround area where parts dry and the volatile organic compounds or VOCs from the solvent in the coating are captured and incinerated to heat the bake oven. There are no VOCs being released into the environment. It’s a very efficient process. The parts spend 10 to 12 minutes in bake oven and then move to offload area. If you wanted to categorize both of these type of application lines, horizontal would be used more for parts used on monumental buildings. The Horizontal line for more the residential sector of building and construction.
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COMPLETED: Learning Objective OneIdentify advantages of the extrusion manufacturing process.
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We’ve now concluded the first learning objective …identifying the advantages of the extrusion manufacturing process. Are there any questions before I move on?
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Discussion
Where have you used interesting coatings on aluminum extrusion products?
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[PAUSE, LOOK UP…STEP TO THE SIDE OF THE LECTERN.] Can any of you think of any examples where you’ve used interesting coatings on aluminum extrusion products?
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Learning Objective TwoIdentify coating components and their role in the coating system.
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Let’s move to Learning Objective Two—identifying coating components and their role in the coating system.
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Introduction to Color and Architectural Coatings
Color consistently a key selling feature for building components Color choices tend to be conservative Heightened consumer and design industry
desire to express creativity through the power of architectural color Looking to color trends and bringing
bolder color choices to projects Poses unique opportunity for high
performance architectural coatings
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A little introduction to Color and Architectural coatings. Color sells but the right color sells even more. One thing company strives for is color that looks good on a building for a period of time and doesn’t look dated. As a result, color choices have tended to be more on the conservative side….whites, beiges, bronzes, metallic, blacks and grays. Now, there’s a trend use more color and bolder color. This is providing an opportunity for manufacturers of high performance architectural coatings to figure out the best ways to formulate brighter colors while still delivering long-term performance and durability in coatings.
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What is a Coating?
Comprised of three principal ingredients:
Additives: Control foam, flow, levelingViscosity Modifiers: Improve settlingCatalysts: Accelerate a chemical reaction
15% 35%Pigments Resin
50%Solvents
Percentages vary by product type and color.
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What is a coating made of? �[LET THE AUDIENCE PROVIDE SOME SUGGESTIONS BEFORE YOU CLICK THE SLIDE A SECOND TIME TO REVEAL THE 3 KEY INGREDIENTS AND PERCENTAGES] The three main ingredients are Pigments, Resins and Solvents. The percentages of pigments, resin and solvents used will vary based on the coating. These percentages you see are typical of a PVDF coating. Pigments supply the color and opacity to hide the substrate so you don’t have show-through—you get nice even color.� Resins are the “glue” or “binder” that holds the coating together and protects the pigment. We generally describe the coating based on the type of resin used because this 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 thin the consistency of the paint to make it easier to apply and provide application properties so you get a nice smooth surface.� Additives can be added to paint to help it flow smoothly when it’s applied and evenly disperse the pigments. They are also used to provide special effects like texture, mar resistance or ability to resist abrasion. Additives are sometimes used to prevent pigment settling in the bottom of the container. There are also additives that can offer additional effects such as texture or lower gloss appearance. 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.
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Introduction to Pigments
Blended to create desired color to suit aesthetics of application
Types of pigments include:• 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
Pigments can:• Provide opacity• Improve corrosion resistance
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Introduction to Pigments Pigments are added to paint to provide color. There are several different pigment types. In most colors, there is a combination of the different types of pigments blended to create the desired color….organic pigments, inorganic pigments and in some cases, there are some specialty pigments, mica, metallic and color changing effect pigments or even Solar Reflective pigments. Pigments also offer additional properties such as total coverage or hide…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 especially good to use if you have a project in an aggressive environment where there are industrial chemicals, or there is ocean-front where there’s airborne salt-spray. The coating system will have the ability to resist corrosion with these corrosive-inhibiting pigments. IF ASKED: Ceramic pigments are extremely well-performing pigment system. They are a subset of inorganic pigments, have good color stability in heat and 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.
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Organic Pigments
Colors from organic pigments can be very bright with vivid appearances Carbon-based Often made from petroleum
Colors from organic pigments tend to be more bright and vivid. You’ll get brighter reds, greens and blues. They are carbon-based and are 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 or 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 high-performance architectural coating to make sure the right color and durability can be achieved.
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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
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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 resistance. 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.
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Pearlescent Pigments
Possess optical effects that serve decorative purposes, offering eye-catching luster Tiny flakes of reflective metal or refractive mica
pigments added into paint mix Several other elements added into paint
production process Unique effect achieved by light interference
rather than light absorption
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Pearlescent pigments give a coating that shiny metallic appearance. They have what we call mica. These are tiny reflective metal or refractive mica pigments that are added to the coating as well as several other elements. When light hits it, the coatings acts kind of like glitter you used as a kid. When the light hits the surface, it scatters the light in many directions. This creates the unique pearlescent effect. We’re seeing a lot more of these coatings used today to differentiate projects.
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Color-Shifting Pigments
Colors appear to change when viewed from different angles or sunlight Combinations of pearlescent mica or aluminum
flakes are used Change in color and degree of color change
controlled by composition and thickness of core and precipitated pigment
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The newer, color-shifting pigments, sometimes called chameleon, are also popular. Automotive started with this type of pigment, and the architectural industry has shifted into this space. Color shifting pigments are added to coatings so that the color shifts when viewed from different angles or sunlight. A combination of pearlescent mica and aluminum flakes are used. I am sure you have seen an automobile with color shifting paint on it. As it is coming towards you it looks one color, when it gets to you it is another color and as it is moving away, it is a different color. Color-shifting pigments can subtle or dramatic depending on the look you want to achieve.
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Color-Shifting Pigments
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California Residence, Woodland, CA
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Here’s a home in California that shows a dramatic color-shifting pigment. The metal panels on this home are all the same color. The owner somewhat wanted to mimic the surroundings and how the color changed through the day based on how the sun hits it. The color-shifting pigments are dramatic. They take on a yellow and almost lime-green hue in the morning and in the evening, they turn from silver to a bronze, brick color. It makes for a nice coating that draws a lot of interest to the structure of the house. The home is so unique that people drive by just to see how the color changes with the angle of light. This effect can be achieved in coil or extrusion coatings.
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Can achieve new and innovative colors using combination of pigments and application process• Richer deeper colors with intense sparkle
• Color-shifting colors that change with angle of light
• Prints that mimic looks such as slate and weathered copper
• Textured appearance
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Special Effect Coatings
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We’re achieving innovative colors with special effects pigments and special application processes. We can achieve richer deeper colors with an intense sparkle, for example. You just saw the color-shifting coatings that change depending on the angle of light. We can also mimic the look of slate and weathered copper. And with special additives, we can achieve a textured look to the coatings.
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Special Effects Pigments
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Textured
Prints
Mica/Metallic
Specialty
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There are more and more new pigment opportunities that labs and the coating industry are using. As an example, here are 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 vary 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.
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Cool Pigment Technology
Metal components coated with solar reflective (SR) pigments keep coating and building cooler • Cool Pigment Technology using infrared pigments improves Solar Reflective
(SR) values and meets LEED and Energy Star requirements
Standard .25 Cool .30Standard .21 Cool .33Standard .67 Cool .72 Standard .47 Cool .56
Standard .08 Cool .26Standard .14 Cool .28 Standard .11 Cool .28
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Here is a technology you may not have heard of – Cool Pigment Technology. The more that you can reflect solar energy from the surface of the metal, the less energy the substrate will need to cool down. So, the metal is coated with SR pigments to keep the building cooler. The pigments are actually infrared pigments and the examples shown here show how different colors can have different SR values….that’s what the numbers represent. Of course, white has the highest level but you can see you can pick a wide range of colors and still achieve the cooling effect. We used these pigments to meet the LEED and Energy Star specifications. Since there are a variety of color palettes with SR pigments, you can consult with your coating and roofing manufacturer for more information if you are considering this approach.
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Discussion
What type of special effects pigments have you used on projects?
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[PAUSE, LOOK UP…STEP TO THE SIDE OF THE LECTERN.] What type of special effects pigments have you used on projects?
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Purpose of Resins
Comprised of polymers Bind paint components together Primary source for a coating’s durability
and physical properties
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Moving onto the resin system. This is typically how coatings are classified for performance based on the resin. The purpose of the resin basically is a combination of what we call polymers. The polymers combine together to produce a very specific resin that gives you specific properties. The main use of a resin is to bind everything together. You want to glue the pigments together to have good adhesive to the substrate. And you want to have a certain degree of performance and durability over period of time time. You want it to have certain physical properties that meet certain specifications…so, for example, if there is some formability that needs to be done on the coating, it can tolerate some slight stretching or bending.
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Resin PerformanceEach resin type offers different outdoor durability performance characteristics.
GOOD
PolyesterGeneric polymer system with limited weather performance; can achieve wide variety of colors because of the organic pigments used.
50% PVDFProvides harder surface, color retention and weather resistance of fluoropolymer coatings.
AcrylicProvides harder surface and high gloss level not seen with PVDFs.
BEST
70% PVDFCurrent state-of-the-art coating. Carbon/fluorine bond is one of strongest chemical bonds known. Non-sticky finish enables pollutants to wash away.
BETTER
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Resin performance. For the most part, the industry is driven by a good, better, best categories—3 categories of quality. On the left, you see the good resin category. This consists mainly of polyester coatings. There are a few acrylic resins that fall into that category. Most of these coatings are designed for non-monumental use…more in the residential space on low-rise structures…They are designed to last for five to 10 years, such as on low-end residential windows where construction management is trying to control cost. In the red section of the slide, 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 low-rise construction such as strip mall centers. Now onto the best category on the right, you have 70% PVDF resins in your coating system. The other 30% would be a modifying resin, such as an acrylic. These 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. IF ASKED: The BEST coating, 70% PVDF, costs 20% more than the better solutions and 80 to 100% more than the good solution. Keep in mind, the coating cost is typically a very small percentage of the building’s overall construction cost.
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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 coalescence
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Presentation Notes
Next, moving onto the Solvent category. Solvents are used mainly to promote good application properties….thinning the paint to control its viscosity, flow and leveling. You choose the solvent based on compatibility with the different resins you 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 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.
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COMPLETED: Learning Objective TwoIdentify coating components and their role in the coating system.
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Presentation Notes
We’ve just completed Learning Objective Two—which was identifying coating components and their role in the coating system. I would ask if anyone has any questions at this point, please chime in.
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Learning Objective ThreeDescribe the coating manufacturing process and coating chemistry.
Presenter
Presentation Notes
Let’s move onto Objective Three—describe the coating manufacturing process and a little bit more about coating chemistry.
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Coating Manufacturing Process
Up to 75 raw materials used to create a color to customer’s exact specifications
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Presentation Notes
Creating a coating formulation that meets the customer’s exact needs in terms of 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. We may use as many as 75 different raw materials to formulate a coating category. The photos are demonstrating automated dispensing equipment used in the industry to combine materials. So you enter your formulation into a laboratory computer, test the formulation to make sure that’s it’s on cue—it’s where it needs to be in meeting formulation specification. Then you produce it automatically in the manufacturing facility. Computers store the formulations and precisely dispense each ingredient. In the photos, you can see barrels of various ingredients. A complex maze of pipes are connected to ingredients to deliver the precise amount to the coating mixing tanks. There are some manual adds, which is demonstrated 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.
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Precise Color-Matching Process
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Same materials and amount dispensed in batch each time specific to customer needs Critical to disperse
pigments adequately in resins and solvents
Presenter
Presentation Notes
During the manufacturing process, part of the formulation is centered around color-matching. Most of the adjustments are done when you mix the materials into the batch of coatings. 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 adjustments related to getting the actual batch of coating on color…color adjustments…and solvent adjustments. A lot of the way this mixing process works is that it’s very similar to making a recipe, where you’re putting all the ingredients together, and then mixing those and making sure they’re processed the way they’re designed to be processed. Sometimes, it can takes 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 a long 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 color-matching batch after batch. That’s a brief look at the coating manufacturing process and the science behind it.
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Coating Chemistry Primer binds top coat to substrate and provides additional anti-corrosion protection. This paint system provides basic protection from exterior conditions that are prevalent.
Paint Coat 1.0 MILS
Primer 0.25 MILS
Substrate(Metallic Coating)
Pigment Particles
Resin
Chemical Conversion Treatment
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Presentation Notes
Coating chemistry…a little bit about the coating film. Starting at the bottom portion of this cross-section of a coating…the gray layer demonstrates the metallic substrate that you are coating over. On top of that is the pretreatment chemical conversion coating. This is a relatively thin layer of pretreatment. This is applied to the metal by the coating applicator to protect against correction 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.� Then over the top of the primer is the actual topcoat. It’s depicted in this image as white with green flecks representing the resin and pigment particles embedded within that resin system. This topcoat is a combination of resin, pigment particles and other ingredients. It is typically applied in 2 coats. This paint coat layer is up to .75 mils thick. There is a lot of innovation that goes into high-performance coatings that they can be so thin yet perform so well. This drawing gives you an idea of the coverage over the substrate, how the coating works and acts as a barrier, providing protection of the substrate, particularly anti-corrosion protection.
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Discussion
Do you have any questions on the coating manufacturing process or coating chemistry?
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Presentation Notes
[PAUSE, LOOK UP…STEP TO THE SIDE OF THE LECTERN.] Let’s pause for a moment and see what questions you might have on the manufacturing process or coating chemistry.
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COMPLETED: Learning Objective ThreeDescribe the coating manufacturing process and coating chemistry.
Presenter
Presentation Notes
We’ve completed Objective Three where I’ve described the manufacturing process and chemistry of coatings in a bit more detail.
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Learning Objective FourIdentify industry standards relative to the performance requirements of coatings for metal building components.
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Presentation Notes
Let’s move onto our Fourth Learning Objective, which is identifying industry standards related to performance for coatings.
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Measuring Color
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∆E = square root of Delta L squared + Delta a squared + Delta b squared from a sample to the standard
“L” axis measures light to dark (white to black)
“a” axis goes from red to green
“b” axis goes from yellow to blue
Measured in three dimensions using standard:
Presenter
Presentation Notes
Measuring color is done using a 3-dimensional method. We refer to it as the L-A-B method. The D in front denotes delta or difference between the known baseline color that you are measuring versus the actual color you are trying to achieve to that baseline standard. This may look like a complicated equation, but it helps ensure a high degree of accuracy when measuring color. It’s pretty simple. Let me walk you through it: The “D-l” value concerns just the lightness-darkness or if you want, white to black, and it’s that vertical access that’s 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, so as you move along that chart, the plus side is red, and the negative side of the chart is green. Likewise, on the third dimension is blue and yellow, which is the “Delta B” scale. It goes from yellow on the plus side to blue on the negative side. Basically, this method is what we use to zero in on color. The idea is when you measure color with the color instrument, when you get the L-A-B values, 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.
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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
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Understanding weather impact on painted metal helps manufacturers develop products to meet specific performance requirements.
Presenter
Presentation Notes
Test and Coating performance. 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.
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Rigorous Exposure Testing
Expect true color: hardworking and weather-tested Perform extensive and continual testing on resins and
pigments to achieve highest industry standards for:• Solar Reflectance
• Retention of color and gloss
• Adhesion
• Finish consistency and quality
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Natural Exposure Accelerated Testing
Presenter
Presentation Notes
Onto exposure testing. Coatings 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 and retain their color AND quality for a lasting impression. They do a lot of testing to look at color fade and chalk…some of the things that are specified in terms of coating performance. There are two types of weather testing, natural exposure and accelerated weather testing. Obviously doing exterior exposure testing takes a long time to do. The photo on the left shows panels being exposed at a 45 degree angle in South Florida, which has the ideal conditions for weather testing because of UV exposure, humidity and salt spray conditions. If you are trying to design and vet a coating that you want 10 to 20 years of good weatherability on, you’ve got a lot of time invested in doing that. Natural exposure is going to show you if a coating will stand the test of time over a period of years. Many panels can be monitored at once and compared. This allows for comparison of resin systems. In conjunction with the actual exterior exposure, many manufacturers also do accelerated testing. Accelerated tests do NOT duplicate natural exposure testing, but they are done in conjunction to see if correlations exist. This is done in cabinets like the ones in the photo on the right. Those are QUV cabinets, and they simulate a very select spectrum of UV light that manufacturers feel is most detrimental to coating. You can select the exact wave length of the light element that goes into those cabinets and alternate cycles of light with water at elevated temperatures. Basically, manufacturers do a lot of correlation with performance for accelerated testing versus natural exposure testing. Between the two, they can determine whether or not a pigment system and a coating system is going to perform up to the standards they are looking for when they’re formulating coatings. They typically do this testing with samples in the industry that customers supply…to running checks to make sure applicators are doing the proper thing for application.
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Physical Tests
Physical tests performed using ASTM test methods to measure:• Color retention
• Film thickness and hardness
• Gloss levels
• Resistance to solvents
• Flexibility
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Presentation Notes
In addition to exposure testing, physical tests are performed to gauge a coating’s performance. Physical test components are mainly driven by ASTM methods…the American Society for Testing and Materials. They are pretty regimented. You can look up specific test methods and it tells you exactly how to conduct the test. We look at a variety of different things using the test. We look at color retention. There’s a method for doing that using a color instrument. We can go back and read a reference standard and read the coated substrate in the field to see exactly how much it’s changed. That’s how we measure color retention…the change from new to aged in the field. � We have different instruments. We can look at film-thickness. These coatings are specified to be at a certain film thickness in order to cover the substrate and offer protection from corrosion. � We also have instruments that can read gloss levels, so you can see whether you’re dealing with a coating that has a gloss level that’s outside the range that you might want. There’s a big difference between gloss level that’s a matt finish when the actual end customer or specifier was wanting something that was a medium gloss. Visually you can see a difference in those two, so we monitor gloss levels using various test methods and instruments.� 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 to actual the rub. That tells us to a degree if the coating will be resistant to certain cleaning methods used in the industry.� And then flexibility. There are tools in the laboratory that we can take the coated substrate and post-fabricated and look at flexibility properties for adhesion and cracking…that sort of thing.
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Discussion
Have any of you had the opportunity to work with a coatings manufacturer on color-matching?
Presenter
Presentation Notes
[PAUSE, LOOK UP…STEP TO THE SIDE OF THE LECTERN.] Have any of you had the opportunity to work with a coatings manufacturer on color-matching? If so, what did you learn from the experience? Were you able to achieve the color you were looking for?
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COMPLETED: Learning Objective FourIdentify industry standards relative to the performance requirements of coatings for metal building components.
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Presentation Notes
We’ve completed Learning Objective Four looking at different industry test methods related to coating performance requirements.
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Learning Objective FiveUnderstand AAMA specifications and specify the best coating for a metal building component or project.
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Presentation Notes
Moving onto the last learning objective today, I want to talk briefly about some of the AAMA specifications related to three different coating qualities I referred to earlier in the presentation.
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AAMA 260570% PVDF
High-Rise Monumental/Residential• Curtain Wall• Wall and Roof Panels• Window, Door Frames• Store Fronts
AAMA 260450% PVDF
High-End Commercial/Condominium• Curtain Wall• Wall and Roof Panels• Window, Door Frames• Store Fronts
AAMA 2603Polyester
Commercial/Industrial/Residential• Interior Extrusions and Panels• Wall and Roof Panels• Window, Door Frames
AAMA Specifications
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Presentation Notes
American Architectural Manufacturers Association, known as AAMA, was started back in 1936. It is basically a group of professionals in the industry, not only from the extrusion industry but from the curtain wall or system manufacturer industry, glass professionals, and skylight/louver professionals. Basically, we all get together as a group 3 times a year to meet and look at existing specifications where we might want to improve or update them or in some cases, look at new opportunities to create specifications for the architectural industry to drive high performance and solve critical issues. The AAMA specifications here are related to high-performance coatings. They are designed to address specific performance needs within the industry and fall into three categories. On the left, you have the highest-performance coatings…AAMA 2605 coating. This is a 70% PVDF coating, most commonly used for high-rise monumental and hig-end residential for long-lasting color. This specification calls for 20-year performance.� In the middle, you have AAMA 2604 coating, which is typically a 50% PVDF and is most commonly used for high-end commercial and condominium structures.� On the right, you have the AAMA 2603 coating, which is typically a polyester resin and used on commercial, industrial and residential structures. �
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AAMA 2605
70% PVDF resins offer the best protection against color fade, chalk, salt spray, pollutants, corrosion and other harsh conditions Applications
• curtain walls
• monumental window wall systems
• louvers
• sun shades
• entry systems
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Presentation Notes
Diving a little deeper into AAMA 2605. This is the highest-end category of coating. 70% PVDF coatings provide the most durable coating there is. They are designed for 20-year performance. They offer the best protection against color fade and chalk, salt spray, pollutants, corrosion, and other harsh conditions. In this category, we’re dealing larger buildings, whether they are a few stories tall or 50 stories tall. Typically curtain wall assemblies are used in these buildings or what’s referred to sometimes as wall and roof panel systems. Also window and door frames that are used in those type of systems and some storefronts. There are number of customers even if they have buildings that are not more than 4 or 5 stories tall that may make the decision to use high-performance coatings to differentiate themselves. There are some store front/strip shop installations that are using 70% PVDF product, or AAMA 2605 too. 70% PVDF coatings have been used around the world on the exteriors of high profile projects. These coatings are the most trusted and known in the industry. They are best to use on monumental projects that need great durability.
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AAMA 2604
50% PVDF containing products provide hard surface with good resistance to chalking and fading Applications
• high traffic areas (interiors)
• store front entry systems
• residential windows
• low rise commercial
• condominium projects
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Presentation Notes
The middle coatings category is AAMA 2604. These buildings are not quite as monumental, and we recommended a minimum of AAMA 2604 or HIGHER coating system for this category for good durability. 50% PVDF containing products may provide a harder surface than a 70% PVDF product line due to a lower PVDF and a higher acrylic content. 50% PVDF resin systems offer good resistance to chalking and fading. AAMA 2604 coatings provide hard, durable surfaces. This is a good product to use in higher traffic areas because of the hardness is a little bit better than the 70%. They are ideal for high traffic areas such as interiors, store front entry systems, residential windows, and low rise commercial and condominium projects. The main differences in the AAMA specification are related to color fade and chalk over a period of time….AAMA 2604 is usually 5-year performance. In addition, there are some differences in salt spray and humidity requirements for 2604 compared to 2605. 2604 is not quite as stringent. All 50% PVDF coatings are a two-coat system similar to the typical, standard 70% PVDF system. They are mainly available in an earth tone color range, although pearlescent systems are now available and widely used.
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AAMA 2603
PVDF/acrylic blends, high solid polyesters, or conventional acrylics that perform extremely well for hardness and weatherability Applications
• non-commercial projects
• patio doors
• recreational vehicle window systems
• outdoor furniture
• monumental (interior) projects
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Presentation Notes
Moving onto the last category, AAMA 2603 coatings. There is some PVDF used in this product, but it’s a very low amount and it’s blended with acrylic resin. They perform extremely well for hardness scratch resistance. In the building and construction segment, these coatings are applied to patio doors, recreational vehicle window systems, and outdoor furniture. They are also widely used for interior applications for monumental projects where you don’t have direct UV exposure. AAMA 2603 coatings are usually a one coat system (direct to metal coatings), and are available in standard and bright colors. A two-coat system with primer and topcoat may be used for specific projects. One of the most important things to remember is there are many factors that come into play when selecting the right coating, so you want to make sure you partner with your coatings supplier to discuss your project so you can select the right coating.
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Discussion
What AAMA coating specification is most relevant for the type of projects you work on?
Presenter
Presentation Notes
[PAUSE, LOOK UP…STEP TO THE SIDE OF THE LECTERN.] What AAMA coating specification is most relevant for the projects you work on?
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COMPLETED: Learning Objective FiveUnderstand AAMA specifications and specify the best coating for a metal building component or project.
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Presentation Notes
With that, we’ve completed Learning Objective Five—a brief overview of AAMA specifications and how they can be used to specify the best coating for a metal building component or project.
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Course Learning Objectives
1. Identify advantages of the extrusion manufacturing process.2. Identify coatings components and their role in the coating system.3. Describe coating manufacturing process and coating chemistry.4. Identify industry standards relative to the performance
requirements of coatings for metal building components. 5. Understand AAMA specifications and specify the best coating for
a metal building component or project.
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Presentation Notes
Wrapping things up, we’ve covered 5 learning objectives today. We’ve described the extrusion manufacturing process and talked a little bit about the details of its main advantages over other manufacturing processes. We’ve identified the components that go into coatings…pigments, resins and solvents their performance characteristics. We’ve been able to describe the manufacturing application process of the coating itself and talk a little bit about coating chemistry. And then we went into industry standard test methods to look at the performance factors of the different coatings that are supplied to the building and construction industry. Lastly, we briefly talked about the different AAMA specifications, the 2605 being the highest-level specification, the 2604 in the middle and the 2603, which is in the good category. Are there any questions or anything else you’d like me to cover? Ok, if you have time, I’ve got another presentation I’d like to take about 5 minutes and show you a bit of detail about Valspar, who we are and what we do as specialists in color services.
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