COAT NOTES

We've Got You Covered


Accelerated Weathering: Part Two

Part One of this blog described some of the difficulties associated with accelerated corrosion testing. The chemistry is complex. There are many microclimates to consider. And the list goes on. There is good news, however. We are not alone. Extensive amounts of research across all coatings areas is done and reported routinely.

french-corrosion-instituteAs a Part Two blog on accelerated corrosion testing, here is a sampling of work done by the French Corrosion Institute, an organization that has done a great deal of work in the past with the European Coil Coating Association. The bullet points following the titles and attributions are my own comments from reading the documents: Continue reading


The Growing Popularity of Metal Roofing in the Residential Market

The Metal Roofing Alliance estimates that more than 750,000 U.S. homeowners chose a metal roof to protect their families in 2015. The Metal Roofing Alliance reports that demand for sustainable, eco-friendly and energy-efficient home improvement materials continue to grow in North America.

According to a new study conducted by Dodge Data & Analytics, the residential metal roofing industry saw a big jump in market share last year, moving from approximately 8 percent in 2014, to 11 percent in 2015. The independent survey showed that between 2014 and 2015, the total demand for metal roofing increased from 11.7 million squares to 17.7 million squares. This is the second time residential metal roofing has achieved double-digit market share in the re-roofing segment. Metal roofing is second only to asphalt shingle roofing in the remodeling market. Asphalt market share dropped 2 points overall, and it now makes up 78 percent of the U.S. market.

When the Metal Roofing Alliance began its national consumer awareness campaign in 1998, metal only made up 3.7 percent of the re-roofing market. The organization’s consistent effort to educate consumers about investment-grade metal roofing has helped to build this market.

Survey Data Continue reading


1 Comment

Accelerated Weathering: Part One

“Not this topic again,” you might say. By “this,” you probably inferred that you are about to read a few hundred words describing the difficulties of meaningfully correlating accelerated weathering to real-time performance. Rest easy; that old topic is kids’ stuff compared to understanding the meaningfulness of corrosion testing.

The performance of coil coatings over the lifetime of a product is of paramount importance. Of the markets served by prepainted metal, the building products market poses the greatest challenges. During a recent NCCA meeting, there were plenty of conversations about accelerated corrosion testing, and this got me thinking about the similarities—and distinct differences—when comparing accelerated corrosion testing and accelerated weathering. Of course, corrosion is a form of weathering, but the term “weathering” commonly refers to what happens to a product’s appearance properties (chalk, fade, gloss retention) when exposed to sunlight, heat and moisture.  On the other hand, corrosion refers to the degradation of the metal substrate.

Great progress has been made over the last 20 years to understand how to model an accelerated weathering test to better simulate the environment in which a product will be placed. We now have a better understanding of the need to duplicate the solar power distribution, the unrealistic effects of <295 nm UV wavelengths, and, most recently, the importance and necessity of coating moisture imbibition in the physio-chemical degradation of coatings. This level of understanding is mostly absent when it comes to accelerated corrosion testing.

What makes corrosion testing so difficult? Let’s start with the chemistry of corrosion versus accelerated weathering. Don’t worry; I do not intend to get into the chemistry and physics. We’ll leave that to the researchers, but it is important to know that these researchers are always striving to duplicate in an accelerated test cabinet the same chemistry that is taking place in the real world. When done effectively, new products can be introduced with an assurance that they will perform suitably in the field.

As demanding as it is to understand the degradation reactions of an organic coating during typical weathering, understanding corrosion reactions is way more convoluted! Continue reading


Securing Coils for Shipping and Related Requirements

The U.S. Department of Transportation, Federal Motor Carrier Safety Administration (FMCSA) provides specific requirements regarding shipping of products, including metal coils. The complete FMCSA requirements can be found in the Code of Federal Regulations. The following provisions of the code relate to securing cargo and safe loading:

  • Shifting or Falling Cargo: FMCSA, 49CFR393.100
  • Safe Loading: FMCSA, 49CFR392.9
  • Rules for Securing Metal Coils: FMCSA, CFR393.120

It is typical for shipping companies to properly secure cargo. Carriers assume responsibility for complying with DOT regulations, and coil coaters do not accept liability for the carrier’s responsibility to properly secure loads. Some companies require their carriers to acknowledge their familiarity with the federal shipping requirements and to agree to abide by the DOT regulations.

Some companies also include signs in their facilities to make drivers aware of their responsibility to be aware of the applicable regulations. An example of such a sign in a coil coating facility follows:

Notice of U.S. Department of Transportation Shipping Regulations: Continue reading


Nine Ways to Get the Most from Your NCCA Membership

 

You already know the tremendous benefits of coil coating metal, but do you know just how much there is to gain with your NCCA membership? Below are just nine ways that the more than 100 industry leaders involved with NCCA get the most from their membership.

Strength in Numbers – One company has limited influence on the media, regulatory agencies and legislatures. When many companies speak with one voice, you command the attention of movers and shakers at the federal, state and local levels. Acting as a unified industry, we speak more effectively and more cost-effectively through NCCA.

Cutting Edge Technology Resources – Through cutting edge technology resources, networking opportunities, educational materials and advanced training tools, NCCA provides critical resources to companies and allows them to grow the market for pre-painted metal. Continue reading


Preventing Job Site Storage Corrosion of Pre-painted Building Panels

coil-coating-process-prepainted-metal-header-image

Prepainted building panels have been successfully used for many years. Properly installed building panels under normal service conditions have excellent corrosion resistance and extremely long life expectancy. However, prepainted building panels may be  subject to premature corrosion failures prior to installation if they are not handled and stored properly on the job site. Excessive storage periods or poor storage conditions can result in water intrusion into panel bundles. Prolonged exposure of bundled panels to wet conditions can cause paint blistering and substrate corrosion.

Environmental and Service Conditions

Water is a necessary prerequisite for corrosion of stored prepainted panels. When water or water vapor is available along the sides of a panel bundle, it may penetrate between the panels by capillary action. If proper precautions are not taken during transport, water may be present between the panels upon delivery at the job site.

Besides water, two other important factors that contribute to the corrosion of stored pre-painted panels are temperature and exposure time. Corrosion will accelerate with increased temperature. Given enough time, panel bundles will eventually become wet and storage corrosion may occur . Customer satisfaction can be increased, and storage corrosion can be prevented by: Continue reading


Five Benefits of Using Coil Coated Metal

Since the 1930s, pre-painted metals have become the superior choice in coating options in a variety of different ways. From going green to saving green, here are just a handful of the reasons why coil coating is becoming the future of the coating industry.

Beauty:

Architects, manufacturers and consumers appreciate the beauty  and benefits of coil-coated metal, including consistent quality, low cost, design flexibility and green properties. Many savvy manufacturers now know that pre-painted metal can be easily fabricated and joined.coil-coating-process-prepainted-metal-header-image

Durability: Continue reading