“Coil Coating”

(Not to Scale) Dual Uncoilers Joiner Entry Accumulator Exit Accumulator Finish Oven Prime OvenCleaning Section Pretreat Section Inspection & Physical Test Area Water Quench Recoiler Shear Prime & Quick Change Coaters Water Quench Finish Coater Overall line length - Approximately 700 feet Strip to thread the line - Approximately 2800 feet Schematic: Typical Coil Coating Line General Overview

Coil Coating: The Process General Overview Receiving Entry Section Cleaning & Pretreatment Coating & Curing Exit End Physical Testing

Record Identity Visual Inspection Obvious Damage –Dents, Torn Paper, etc. –Wet? Material Handling Crane or Forklift Store for Future Use Capacity: 3 Mos. Coil Coating: The Process Receiving

Coil Coating: The Process General Overview Receiving Entry Section Cleaning & Pretreatment Coating & Curing Exit End Physical Testing

Get Steel l- FIFO & ID Check Metal Specifications –Grade/Gauge/Wi dth/Etc. –Quantity/Coil Size Check Condition –Edges –Shape –Zinc Surface Coil Coating: The Process Entry Section

Coil Cars Floor or Pit Pay Off Arbors Coil Size –Width –ID or OD & Weight Joiner/Welder Coil Coating: The Process Entry Section I

De-burring Rolls Pre-cleaner Entry Bridle Entry Tower Hydraulic/Electric Coil Coating: The Process Entry Section II

Receiving Entry Section Cleaning & Pretreatment Coating & Curing Physical Testing Exit End Coil Coating: The Process General Overview

Rinse Clean & Brush Clean & Rinse Chemical Treatment –Single or Multi-Stage Final Rinse Waste Treatment; Chrome Coil Coating: The Process Cleaning & Pretreatment I

The key to quality is preparing the metal to accept the paint. Pretreatments enhance the corrosion resistance of the system. The type of pretreatments used depends on the base metal. −Galvanized - Zinc Phosphate 37S −Galvalume - Chromate Oxide 1310 −Final Rinse - Parcolene 62 Chromic Acid −Dried-in-Place Coatings: 1402W (some Cr. free) −Duplex Complex Oxide or Zinc Phos. & 1402W Coil Coating: The Process Cleaning & Pretreatment II

Coil Coating: The Process Cleaning & Pretreatment III  A liquid used to produce a corrosion-resistant, organically bonded coating on Aluminum, Galvalume and Galvanized.  Incorporating a chromate rinse which is the major agent that allows the primer to bond to the substrate and helps prevent corrosion.  Benefits of Pretreatments: Provides superior long term corrosion. Effective on Aluminum, Galvalume and Galvanized. Coating quality is consistent.

Receiving Entry Section Cleaning & Pretreatment Coating & Curing Physical Testing Exit End Coil Coating: The Process General Overview

Specification –Primers, Backer, Topcoat –Cure time & Line Speed Coater Paints Topcoat & Backer at the Same Time Usually Two Complete Sets −Coater, Oven and Quench for Primers and finish Coats Line Direction Coil Coating: The Process Coating & Curing I

Coil Coating: The Process Coating & Curing II Coating Speeds up to 650 fpm –Speed dependent on cure requirements, gauge and solvent loads Ovens mostly Cantenary Type to 160 ft. long Cure is Determined by Peak Metal Temperature Cure Occurs in Seconds

Coil Coating: The Process Coating & Curing III - PRIMER  The base layer of the paint applied by the coater to the pretreated substrate.  It is formulated to provide corrosion protection to the base metal and to enhance adhesion between the top coat (paint) and the base metal.  Standard Primers: Water Based Urethane Based

Receiving Entry Section Cleaning & Pretreatment Coating & Curing Physical Testing Exit End Coil Coating: The Process General Overview

Utilize a Color Difference Meter Assigns value corresponding to the amount of light at each wavelength Value is compared to and held in tolerance of Color Standard Coil Coating: The Process Physical Testing – Hunter L.A.B. L = +0.2 a = -0.4 b = -0.3 Specimen Light SourceDiffraction Grating Diode Array Data Processor Data Display

5/8” diameter steel ball is dropped from a prescribed height onto the panel. Effect leaves a deformation that is subject to cross hatch and tape test. Tape (Scotch #610) is aggressively adhered and pulled (not peeled) away from the sample. Coil Coating: The Process Physical Testing – Reverse Impact Adhesion

Brake press forming of metal sample Tape (Scotch #610) aggressively applied and pulled away Coil Coating: The Process Physical Testing – Flexibility

Scribe cut with calibrated blade Visual inspection with reticle enable microscope Measures Primer DFT Measures Topcoat DFT Tooke Gauge Coil Coating: The Process Physical Testing – Film Thickness

MEK = Methyl Ethyl Keytone Indicates Proper Cure Solvent is liberally applied and cheesecloth is stroked back and forth across panel face for prescribed # of strokes Coil Coating: The Process Physical Testing – Solvent Resistance

Instrument measures reflected gloss Typically measured at 60° Ultra low gloss measured at 85° Coil Coating: The Process Physical Testing – Gloss Meter

Receiving Entry Section Cleaning & Pretreatment Coating & Curing Physical Testing Exit End Coil Coating: The Process General Overview

Recoil Coil Tipper - Coils Eye to the Sky Package - Paper Wrap & Skid Tag/Record Store or Ship Coil Coating: The Process Exit End