Painted Coil Sheet
Coil dyeing is a continuous dyeing process based on high automation applied to flat metals in roll form with polyurethane rollers. Painted sheets are produced in continuous lines consisting of the following steps.
- The coil is opened, the upper and lower surfaces are cleaned (washed and rinsed with special chemicals),
- The upper and lower metal surfaces are chromated (a process that increases corrosion resistance and strengthens the adhesion of the paint) and baked.
- It is primed (only for front surface painting, back paint with high polyurethane adhesion is applied to the back surface) and baked.
- In double surface painting, the requested top coat paint is applied on the primer and baked.
- Protective film is applied depending on customer demand,
- Painted metal is rolled and packaged in rolls.
PAINTED SHEET PRODUCTION LIMITS
| (PPGI) PRE-PAINTED GALVANIZED STEEL | Min. (mm) | Max. (mm) |
| Kalınlık I Thickness | 0,25 | 3,00 |
| Genişlik I Width | 800 | 1530 |
| Rulo İç Çapı I Coil’s Inner Diameter | 508 | 610 |
| Rulo Dış Çapı I Coil’s Outer Diameter | – | 2200 |
| Rulo Ağırlığı I Coil Weight | 1000 kg. | 22000 kg. |
| Kaplama Miktarı I Coating Weight | 60 gr/m2 (both sides) | 600 gr/m2 (both sides) |
| Levha Boy I Sheet’s Length | 500 | 6000 |
| Paket Ağırlığı I Weight of Sheet’s Package | – | 8000 kg. |
| Dilme genişliği I Slitting Width | 40mm | – |
| Renk I Colour | Ral Renkleri – Ral Colours | |
| Boya Tipleri I Coating Type | Polyester (PE), PVDF, Plastisol (PVC-P), PUR-PA, PUR-PE, PVC, Wrinkel Polyester, HD Polyester. |
PRINTED SHEET USAGE AREAS
A- In the Construction Sector
Sandwich panel and composite panel production
Exterior, roofing and metal tile production
In agricultural and military building (hangar) construction products
In rain gutter production
In the production of building entrances, garage doors and shutters made of metal
In the production of suspended ceiling panels and parts
In the production of modular interior building materials
B- Durable Consumer Goods
In white goods production
DVD, receiver production
C- In Heating Systems
In the production of air conditioners and fans
D- In the production of lighting fixtures and electrical panels
E- Billboards and Industrial design applications
F- In the Agriculture-Livestock Sector: It is used in the production of silos and animal shelters.
DYED SHEETS PRODUCED DEPENDING ON THE PAINT TYPE
Considering the types of polymers that play the role of binder in the content of the paint used, painted sheets can be classified as follows;
- Polyester (PE) Based Painted Sheets: The strongest aspects of polyester paints are that they have a wide range of color and gloss options and they are economical. For this reason, they find a very common usage area. In addition, flexibility, abrasion resistance, corrosion resistance, moisture resistance and impact resistance are also good. Their low external strength, chalking resistance and gloss resistance can be listed as their weaknesses. Polyester paint thicknesses are applied between 20-25 μm depending on the usage area of the painted sheet and the expected performance.
Although higher thickness applications are possible, it is not preferred because it shows weakness in terms of flexibility and surface appearance quality. Common usage areas of polyester painted sheets are; roof cladding, sandwich panels, garage doors, suspended ceilings, seam construction, white goods products and rain water drainage systems. - Super (High Durable) Polyester-Based Painted Sheets: It is a type of paint, which has a higher color resistance and bendability than standard polyester paints, and which has been increasingly used in recent years and is especially preferred in facade cladding such as composite panels. While the UV resistance of polyester paints is evaluated as RUV2, super polyester paints are evaluated in the RUV4 class, just like PVDF paints. The application thickness is between 20-25 μm as in polyester paints.
- PVDF Based Painted Sheets: The strongest aspects of PVDF paints are their excellent color and gloss resistance, chalking resistance and resistance to many chemicals. Flexibility, impact and abrasion resistance are also good. Their weak points are that they have low scratch resistance, color and gloss options are not as diverse as polyester paints, and they have lower coating areas compared to polyester paints. PVDF paint thicknesses generally vary between 20 μm and 25 μm.
Common usage areas of PVDF painted sheets; Since they have the best color and gloss stability among paint types, they are preferred in roof cladding, sandwich panels as well as composite production and advertising panels in areas where the sun is very effective.
Polyurethane-Based Painted Sheets: This paint type is very high scratch and friction due to polyamide reinforcement.
What resistance does it have? Polyurethane-based paints can be applied as plain or patterned (PURPA Texture). Corrosion resistance, color and gloss resistance and formability are also good. Although the common application thickness of polyurethane paints is 20-25 μm, thicker applications are also possible. Common usage areas of polyurethane-based painted sheets; Due to their high scratch resistance, they are preferred in applications where scratch resistance is important, such as garage doors and roller shutter production. Roof and facade coatings are other areas of use. - Wrinkle Polyester Based Painted Sheets: Bending properties are high as in polyamide based paints. It is a painted sheet that can make a visual difference due to its particle and textural structure being different from other paints. It is especially used in roofing cream construction. The paint thickness depends on the type of texture and color requested.
- Plastisol (PVC) Based Painted Sheets: They have much higher application thicknesses compared to other paint types. Dry film thicknesses of 100-200 μm are commonly used. Very good corrosion and moisture resistance are their strongest points. They are suitable for bending and shaping in terms of paint type. One of their important features is that they are suitable for embosser (embossing) application. Color and gloss durability can be stated as their weakest points. For this reason, they are widely used in regions where the sun’s rays are not very effective (eg Northern Europe). Common usage areas of plastisol-based painted sheets; Applications requiring high corrosion resistance and roof-facade coatings where UV resistance is not very important.
PAINTED SHEET PRODUCTION TOLERANCES
| Boyalı Sac Üretim Tolerans Tablosu | |||
| Boyalı Sac Üretim Tolerans Tablosu | Polyester, Polivinil, Poliüretan | Plastisol | |
| Sac Üretim Tolerans Tablosu | Standart: | Üst yüzeyin toplam kaplama kalınlığı | Şartname ± %10 |
| 20±2mm | 25±3mm | ||
| Metalik Renk: | Metalik renk kullanıldığında üst | ||
| 81±2mm | Yüzeyin toplam kaplama kalınlığı | ||
| Üst ve Alt Yüzeyin Astar Kalınlığı | 4-6mm (5±1mm) | 23±3mm | 4-6mm (5±1mm) |
| Alt Yüzeyin Kaplama Kalınlığı | – | 7±1mm | – |
| Üst Yüzeyin Boya Renginden Sapma Tol. | ΔE≤1 Metalik, Fosforlu ve Sedefli için | ΔE≤2 | |
| 60° Sıcaklıkta | mat: ≤10 | mat: ≤10 | |
| düşük parlaklık: >10- ≤20 | düşük parlaklık: >10- ≤20 | ||
| orta parlaklık: >20- ≤40 | orta parlaklık: >20- ≤40 | ||
| parlaklık: >60- ≤80 | parlaklık: >60- >80 | ||
| yüksek parlaklık: ≥80 | yüksek parlaklık: >80 | ||
| Üst Yüzey Kaplamasının Silinmesine Yönelik MEK Testi | ≥100 | – | |
| Metalik Renk ≥50 | |||
| Alt Yüzey Kaplamasının Silinmesine Yönelik MEK Testi | ≥50 | ≥50 | |
| Kaplamanın Üst Tabakası/Adezyon Testi | ≥6mm-0 | ≥6mm-0 | |
| Alt Yüzey Kaplamasının Adezyon Testi | ≥6mm-0 | ≥6mm-0 | |
| Alt Yüzey Kaplaması Kalem Sertiği Testi | Min.F | – | |
| Üst Yüzey Kaplaması T Bükme Testi | Max.2,5 T | Max.0,50 T | |
| Darbe Testi | ≥10 j | – | |
- Pencil hardness is not considered for paints containing polyamide, PVC and wrinkle paints.
- Pencil hardness and MEK tests are not performed for plastisol paints.
- The reverse impact test for paints containing polyamide is 4J.
- Gloss production is not performed in PVDF paints.
DYED SHEET COLOR OPTIONS (RAL CATALOG COLORS)
RAL is a color matching system generally used in Europe. It was developed to describe colors. Today, it is generally used in the Painted Sheet sector, but it is also frequently used in other sectors. RAL first started with 40 colors, then it developed and reached over 1900 color series.
The RAL Classic collection has attracted great attention all over the world, especially in its collection. Color names according to their usage areas are also named after the warning and traffic signs, government institutions and public services where those colors are used. (For example: RAL 1004 – Swiss Postal Service, RAL 1021 – Austrian Postal Service, RAL 1032 – German Postal Service).