METALLIC COATED STEEL Metallic coated steel is used when a good corrosion protection is required.

Grades Tata Steel manufactures a variety of metallic coated steels with properties for many different applications. Coatings Three types of zinc coating are available: Pure zinc Steel is coated with a almost pure zinc coating (>99% zinc). Iron-zinc alloy Steel is coated with a zinc coating containing approximately 8-12% iron. MagiZinc MagiZinc is the innovative metallic coating of Tata Steel. This coating offers improved corrosion protection allowing reduction up to 50% of the zinc coating thickness against a competitive cost. Any application which asks for galvanised steel could be subject for a change to this revolutionary metallic coating. MagiZinc is a zinc coating that incorporates a small fraction of magnesium and aluminium and is a major breakthrough in corrosion protection. Benefits: - Superior corrosion protection - Improved yield Given the same core steel thickness, and half the usual layer of zinc, a tonne of steel simply produces more square metres. The thinner and lighter coating results in up to 4% more m2 per tonne material, depending on the thickness of the steel. - Physical qualities Treated with our second-generation chromium-free passivating agent, MagiZinc has outstanding processing properties. MagiZinc is also perfect for deep drawing, ensuring excellent paint adhesion, while the reduced coating thickness improves weldability. An

additional benefit is that the coated surface is harder. This improves both scratch and wear resistance. All types of metallic coated steels offer the economy, strength, and formability of steel combined with the corrosion resistance of zinc.

TYPES OF COATINGS Structure Polymer coated coiled steel consists of several layers, and each of them plays an important role in creating polymer coated steel of super quality.

Metallic substrate Besides hot dipped galvanized steel, other types of metallic coatings are used: Al-Zn alloy coating, cold-rolled steel, cold-galvanized steel, aluminium band. Irrespective of the type we use a single common name for the products - polymer coated coiled steel. Materials used: Zinc-coated steel Cold-rolled steel sheet passes through a tank with melted zinc and undergoes the process of galvanization during which both sides of a steel sheet are covered with a coating of equal thickness. Depending on a method of processing the surface of a galvanized metal sheet, the latter can be a sheet with normal crystals, minimized crystals or an ultra-smooth sheet with zero crystals. In production of polymer coated coiled steel ultra-smooth material is used. Special inc-coated steel A steel sheet, coated with zinc-aluminium alloy, for products required special processing characteristics. Cold-galvanized steel sheet band (EGI) The surface of a cold-galvanized steel sheet undergoes matting, and then both its sides are coated (weight of zinc - 13g~25 g/m). Electro galvanized steel is usually used in household appliances. Thanks to small specific weight of zinc, it cannot be used in products required high corrosion resistance.

Aluminium band Thanks to its high corrosion resistance, aluminium is widely used in production of finishing materials, composite panels, etc. COATING The following types of coatings can be deposited on a steel band: Polyester (PE, SP) The most popular polymer on the market of polymer coatings used for zinc-coated steel sheets, which adds to paint-coated steel high resistance to UV-radiation and corrosion, is polyester (polyester). This material has a high level elasticity and formability and can be used in any climatic conditions. Mechanical durability of this type coating is lower than of pural and PVDF coatings. A somewhat higher mechanical durability has quartz sand polyester. Most frequently used coatings are the ones based on saturated polyethers (SP, PL). The base material for the coating is polyether paint of high color retention. Its thermal endurance index under sun rays exposure is as high as +120, and the lower temperature limit for polyester is -60. Polyester layer thickness on paint-coated steel is up to 25 m. Matted polyester () Polyether coating of 35 m thickness with matted surface is teflon-modified polyester. This material has high color retention thanks to an optimal refraction index for the sun radiation, and high corrosion and mechanical resistance; it does not change its characteristics in any climate. This material is used when the absence of gloss on a product is of utmost importance. Plastisol (PVC-200) This decorative polymer for the thickest coating (200 m), consists of polyvinylchloride (PVC) and plasticizers, having a textured surface. Thanks to thicker coating, the material is one of the most resistant to mechanical damages. Nevertheless, for the low temperature resistance and UV-radiation resistance (when heated by direct sun light above +80 the material undergoes quick aging) it is not recommended to use the material in southern regions. Having thicker coating, plastisol is characterized by its high corrosion resistance, which creates an additional protection means in the polluted environment. Its color retention is substantially lower than that of polyester. Plastisol coating of thickness 175 m is produced only with a smooth surface. A coating of thickness 200 m can be roller-embossed, which produces a texture-patterned surface.

PURAL This coating based on polyamide-modified polyurethane has a silky matted structural surface. This material has high resistance to substantial daily temperature variations (up to 120). The material has high chemical stability and color retention. It is also mechanically resistant. Though, relative to plastisol, pural has lower resistance to plastic deformation. Thickness of the coating is 50 m. PVDF The coating of 27 m thickness consists of polyvinylchloride (80%) and acryl (20%). This strong and the most UV-radiation resistant coating does not practically fade, has a fine gloss, and is self-washable. The glossy finish of PVDF coating may have a metal hue of silvery or copper tints. For adding metallic gloss, a standard PVDF coating is furnished with a transparent varnish layer with metallic pigment. This is the most long-lasting coating, used even in such corrosive environment as seashore. Acryl Acryl is a varnish-and-paint layer which is very unstable; it can be easily damaged while installing the product. It has a good thermal endurance up to +120, but it fades in the sun during a 5 year period. Besides, it has a moderate resistance to corrosion. The layer is 25 m thick. Minimal processing temperature is -10.

PREFABRICATION PRIMERS Also referred to as blast primers, shop primers, temporary primers, holding primers, etc., these primers are sometimes used on structural steelwork, immediately after blast cleaning, to maintain the reactive blast cleaned surface in a rust free condition until final painting can be undertaken. They are mainly applied to steel plates and sections before fabrication. The main requirements of a prefabrication primer are as follows: The primer should be capable of airless spray application to produce a very thin even coating. Dry film thickness is usually limited between 15-25m. Below 15m, the peaks of the blast profile are not protected and 'rust rashing' occurs on weathering. Above 25m, the primer affects the quality of the weld and produces excessive weld fume. The primer must dry very quickly. Priming is often done in-line with automatic blast cleaning plant which may be handling plates and/or sections at a pass rate of between 1-3 metres/minute. The interval between priming and handling is usually of the order of 1-10 minutes and hence the primer film must dry within this time.

Normal fabrication procedures (e.g. welding, gas cutting) must not be significantly impeded by the coating, and the primer should not cause excessive weld porosity. A welding certificate should be available from the paint manufacturer. Weld fume omitted by the primer must not exceed the appropriate Occupational Exposure Limits. Proprietary primers are tested and certified by the Newcastle Occupational Health Agency. Ahealth and safety certificate should be available from the paint manufacturer. The primer coating should provide adequate protection until either overcoated or placed within a non corrosive environment e.g. indoor storage or within a building construction. In practice, such periods are rarely met except in the least arduous conditions, e.g. indoor storage. In aggressive conditions, durability can often be measured in weeks rather than months. Zinc rich and zinc silicate primers provide the highest order of protection of all prefabrication primers. The primed surface, after weathering, should require the minimum of repreparation for subsequent painting and must be compatible with the intended paint system. Many proprietary prefabrication primers are available but they can be classified under the following main generic types:

Etch primers These are based on polyvinyl butyral resin reinforced with a phenolic resin to increase water resistance. These primers can be supplied in a single pack or two pack form, the latter providing better durability. Epoxy primers These are two pack materials utilising epoxy resins and usually have either polyamide or polyamine curing agents. They are pigmented with a variety of inhibitive and noninhibitive pigments. Zinc phosphate epoxy primers are the most frequently encountered and give the best durability within the group. Zinc epoxy primers These primers can be either zinc rich or reduced zinc types. Zinc rich primers produce films which contain about 85% by weight of metallic zinc powder and the reduced zinc type as low as 55% by weight. When exposed in either marine or highly industrial environments, zinc epoxy primers are prone to the formation of insoluble white zinc corrosion products which must be removed from the surface before subsequent overcoating. Zinc silicate primers Zinc silicate primers produce a level of protection which is comparable with the zinc rich epoxy types and they suffer from the same drawbacks, e.g. formation of zinc salts and

production of zinc oxide fume during welding. There are currently different categories of zinc silicate primers based upon the binder (organic or inorganic) and the zinc content. Low zinc primers in this group have been developed to improve their weldability and to minimise weld porosity, however their durability is also reduced. The organic silicate primers are the most suitable as prefabrication primers.

PAINT COATINGS Paints are usually applied one coat on top of another and each coat has a specific function / purpose. These are described as follows. Primers The primer is applied directly onto the cleaned steel surface or, in the case of duplex systems, the sealed metal coating. Its purpose is to wet the surface and to provide good adhesion for subsequently applied coats. For primers applied directly to steel surfaces, these are also usually required to provide corrosion inhibition. There are two basic types of primer. (a) Primers pigmented with metallic elements anodic to steel These primers are formulated so that, when a break in the coating (due to damage or local corrosion) exposes the steel substrate, the anodic metal corrodes sacrificially in preference to the steel. This effectively stifles steel corrosion and under-rusting of the primer until the anodic metal is exhausted. Zinc-rich primers are the most commonly used of this type. (b) Primers relying on the high adhesion and chemical-resistance properties of the binder With these primers, good adhesion is obtained (provided that the surface is very thoroughly cleaned) and it is sufficient to prevent under-rusting at any break in the coating (due to damage). Two-pack epoxy primers are typical of this type. These primers may contain inhibitive pigments to interfere with the corrosion process. Zinc phosphate, for example, is a mildly inhibitive pigment and is widely used in modern primer formulations.

Intermediate coats Intermediate coats are applied to build the total film thickness of the system. Generally, the thicker the coating the longer the life. Intermediate coats are specially designed to

enhance the overall protection and, when highly pigmented, decrease permeability to oxygen and water. The incorporation of laminar pigments, such as micaceous iron oxide (MIO), reduces or delays moisture penetration in humid atmospheres and improves tensile strength. Modern specifications now include inert pigments such as glass flakes to act as laminar pigments. Undercoats must remain compatible with finishing coats when there are unavoidable delays in applying them.

Finish coat The finish coat provides the required appearance and surface resistance of the system. Depending on the conditions of exposure, it must also provide the first line of defence against weather and sunlight, open exposure, and condensation.

Stripe coats Stripe coats are additional coats of paint that are applied locally to welds, fasteners and external corners. Their function is to build a satisfactory coating thickness at edges and corners where paint has a tendency to contract and thin upon drying. Specifications should indicate the type and number of stripe coats required and state when they are to be applied.

THE PAINT SYSTEM The various superimposed coats within a painting system have, of course, to be compatible with one another. They may be all of the same generic type or may be different, e.g. chemical resistant types, such as a recoatable polyurethane finish coat, may be applied onto epoxy primer and intermediate coats. However, as a first precaution, all paints within a system should normally be obtained from the same manufacturer and used in accordance with the manufacturers recommendations. An important factor in the coating system is the definition and measurement of the dry film thickness (dft). Dry film thicknesses are generally checked on the complete paint system, although individual films may be checked separately. Usually, nominal dry film thicknesses are specified but sometimes minimum values are quoted.

For nominal dry film thicknesses, individual values less than 80% of the nominal thickness are not acceptable. Values between 80% and 100% are acceptable provided that the overall average (mean value) is equal to or greater than the nominal. Specifications for minimum dry film thicknesses require careful paint application to avoid excessive film thickness. The over application of paints can result in the formation of high stresses and may cause premature failure of the system. Wet film thickness (wft) checks may also be required during the application of the coating to check that a subsequent satisfactory dry film thickness will be achieved.