Raw materials and coatings - basic training
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Raw materials and coatings - basic training

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For construction professionals and sales personnel. ...

For construction professionals and sales personnel.

The material will take you through the basics of raw materials and coatings as well as describes how to use them in different applications. After studying the material you will:

* Know the basics of raw materials and coatings
* Know the newest products in coatings
* Get introduced to how different coatings and steel grades are used in construction applications
* Know some technical performance of the coatings
* Get a deeper overview of the two newest coating options
* Get some important tips maintenance-wise

Read more about steel coatings:
ruukki.com/colourcoatedsteels
ruukki.com/metalcoatedsteels

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Raw materials and coatings - basic training Raw materials and coatings - basic training Presentation Transcript

  • Coil coated steel Raw material & coatings
  • Contents Production Production stages PVDF Coatings, main lines Steel grades Coatings, products
  • Production
    • The high quality of our products is based on the hot rolled steel manufactured at our works in Raahe, Finland
    • Cold rolling takes place at the Hämeenlinna Works which employs nearly 1000 professionals of production, product development and customer service
    Hämeenlinna works
  • Production – raw materials Malmberget Luleå Raahe Gotland Import Porvoo Hämeenlinna Mustavaara (1 000 t) Iron ore 3 400 - Sweden 3 000 - Mauritania 300 - Finland 100 Coaking coal 1 200 - USA, Canada 800 - Australia 400 Blast furnace oil - Finland 300 Limestone - Sweden 650 Recycled steel 700 - bought 200 - own 500 Zinc 40 Alloying element 50 Paints 10 Million litres Oxygen 42 000 m 3 /h Electricity 1 100 GWh - bought 400 GWh - own 700 GWh Liquefied and natural gas 870 GWh
  • Production stages Cold rolling Metal coating *) Iron- making Steelmaking Production of tubular products; tubes , sections Plates, Prefabricated plate products Hot-rolled strip products Cold-rolled products Metal-coated products *) Colour-coated products Tubular products Plate rolling Hot strip rolling *) Hot-dip zinc-coated steels Galfan ® ; zinc-aluminium alloy coated steels Galvannealed; zinc-iron alloy coated steels Skip this part Mineral p roducts
  • Iron- and steelmaking Back to production map Limestone Iron concentrate Coal Oxygen Oil Sinter Pellets Coke Coking plant Sintering plant Oxygen plant Lime burning kilns Blast furnace Recycled steel Slab Desulphurisation Converter Ladle furnace Vacuum degassing Continuous casting Raw iron Steel Oxygen
  • Production of mineral products Extraction of recycled steel Back to production map Coal Iron concentrate Limestone Lime kilns Coking plant Sintering plant Pellets Sinter Coke Oil Oxygen Blast furnace Air cooling Granulation Desulphurisation Converter Recycled steel Oxygen Steel Ladle furnace Slag Slag Vacuum degassing Continuous casting Slab Blast furnace slag Mineral products to customers Slag Transportation of molten slag Crushing and screening Earthworks and road construction Agriculture Construction industry Flame cutting Recycled metals Process Customers
  • Plate rolling Direct quenching and accelerated cooling Hot leveller Pusher type slab reheating furnaces Slab Plate mill Normalising furnace Hot leveller Inspection Cooling banks Marking Pre-leveller Cold leveller Plasma cutting Flame/ mechanical cutting
  • Plate products Plates Jet cleaned and primed plates Precision cut and bevelled plates Jet cleaned and primed plates Shape flame- cut plates Wide flats Painting Bevelling Shape flame cutting Wide flat flame cutting Bending Curved plates Flame cutting Flame-cut plates Back to production map
  • Hot strip rolling Walking beam furnaces Finishing mill Coil box Vertical edger Strip cooling Coilers Slab Roughing mill
  • Strip products Back to production map Cut lengths Slit strips Pickled coils Pickling Slitting line Cut-to-length line Patterned plates Hot-rolled coils Hot-rolled coils Skin pass mill
  • Cold rolling and coating *) Hot-dip zinc-coated steels Galfan ® ; zinc-aluminium alloy coated steels Galvannealed; zinc-iron alloy coated steels Pickling Cold rolling Annealing Temper mill Metal coating *) Slitting Colour coating Cutting to length Cold-rolled steel sheets and coils Metal-coated *) steel sheets and coils Colour-coated steel sheets and coils Recoiling
  • Coil coating Back to production map 1424 mm
  • Tube production – longitudinally welded tubes Uncoiling Splicing Strip accumulator Forming Bundling, strapping and delivery Final inspection and marking Oiling and cutting Calibrating and shaping Cooling and testing Weld trimming HFI welding
  • Tube production – spirally welded tubes Back to production map Hot-rolled coil Forming, submerged arc welding and cutting Finishing, testing and inspection Delivery External PE coating Internal colour coating External PE coating
  • Section production Back to production map Uncoiler Coil opener Punching Leveller Profiling Levelling Cutting Bundling Strip welding
  • Coatings
    • Metal coated steel sheets and coils
    • Ruukki’s metal coated steel products offer a combination of high-strength and formable steels and corrosion resistance from the coating
    • Our extensive manufacturing programme enables you to combine exactly the characteristics required for your application
  • Coatings
    • Coating options
    • Zinc coating
      • The traditional zinc coating provides a good level of corrosion protection for normal applications
    • Galfan® zinc-aluminium alloy coating
      • This coating system provides clearly superior formability compared with the traditional zinc coating
      • Galfan is well suited for demanding deep drawing
    • Galvannealed zinc-iron alloy coating
      • The iron content of this coating gives Galvannealed coated steels outstanding weldability. Adhesion on the matt surface is excellent, creating a first class surface quality in the end product
  • Coatings
    • Colour coated steel sheets and coils
    • Colour coated grades represent the best of Ruukki know-how in steels and their coatings
    • The ready for use surface conceals several new characteristics carefully tailored to the customer’s specific requirements
    • Coating options are introduced precisely later in this presentation
  • Coatings
    • Zinc coating
    • 100- 225 g/m 2 , when used indoors
    • 275 g/m 2 when used as a factory coating indoors and outdoors
    • 350 g/m 2 to use outdoors without coating or when the coating is made on site
    • The total mass is a combined sum from both sides
    • For very demanding conditions it is possible to have 450g/m² zinc coating
  • Coatings – zinc coating
    • *) g/m² means, that there is this amount of zinc, when you calculate an area that is one square meter-sized
    • **) The thickness of the coating ( µm) is the average, counted from three tests. It is a reference value that tells the thickness on one side. The values in brackets (in above table) are indicative
  • Coatings – zinc coating
    • Normal quality MA, allows minor roughness, size alternations in solidification pattern, dark spots, small gaps, line-like marks and slight passivation stains
    • Horizontal stretcher strains from stretch leveling or zinc run-off marks are allowed
    • If one wishes to paint the zinc coated surface on site, surface quality MA is recommended
  • Coatings – zinc coating
    • Demanding quality MB is made by skin pass rolling. This quality allows only small surface imperfections, such as horizontal stretcher strains from stretch leveling, skin pass marks, scratches, indentations, spangles, zinc run-off marks, and minor passivation marks. No holes or gaps are allowed.
    • If one wishes to paint the zinc coated surface on site, surface quality MB can also be used
  • Coatings – zinc coating
    • Very demanding surface quality MC is made by skin pass rolling. The better surface quality of this product doesn’t affect notably on the solid appearance of the final painted product
    • If you paint coat the zinc coated product in factory, the surface quality must always be MC
  • Coatings – zinc coating
    • Unless otherwise agreed, the zinc coated surface is always protected against white-rusting with chemical passivation (marked C, product=Cr 3+ )
    • If desired, oil protection can also be used (marked O), or both together (marked CO)
    • It is also possible to get the product without protection at all (marked U)
    • Bear in mind that no product, that can be used on site, will remove the passivation!
  • Steel grades (for coil coating)
    • Structural steels
      • S280GD + Z
      • S320GD + Z
      • S350GD + Z
    • Formable steels
      • DX51D + Z
      • DX52D + Z
      • DX53D + Z
      • DX54
      • S220 and S250
  • Steel grades – tinsmith quality
    • Tinsmith qualities are easy to bend and work with
    • Doesn’t age
    • Storage doesn’t effect on strength. The softness is guaranteed also for paint coated sheets. The same strength as coated also
    • Elongation to fracture: this means the sheet’s stretchability, without splitting
    • Traditional seaming quality Z02 = DX52D
    • This sort of qualities differ from factory made profiles, which are much harder to bend and work with!
    Elongation min . DX51D DX52D DX53D DX54D 300 260 220 (340) 22 26 30 36 This feels in hands as hardness or softness Traditional seaming quality N/mm² %
  • Steel grades – applications
    • RSP, CL – DX51D
    • Design Profiles – S320GD
    • Profiled/corrugated sheets – S280GD - S350GD
    • Composite panels – S280GD - S320GD
    • Liner Tray – structural steel S280GD
    • Load bearing profiles – S320GD - S350GD
    • Tile sheets – S280GD
    • Classic – S320GD
    • RWS – DX52D & DX53D
    • APX – DX53D
  • Standard zinc coatings
    • 275g/m 2 – optimal amount of zinc, when organic coatings are used
    • 140g/m 2 + 50g/m 2 – A + B side (composite panels)
    • 350g/m 2 – unpainted outdoor application
    • 100g/m 2 – indoor application only
  • Coatings
    • Polyester
    • Polyester matt
    • Pural
    • Pural matt
    • PVDF
    • PVDF matt
    • Purex
    Laminates
    • PVC Laminate
    • Food Safe – laminate
  • Polyester
    • Thickness 25 µm
    • Smooth and glossy surface
    • Fairly good UV and corrosion resistance
    • Good formability, large range of colours
    • Polyester is recommended for interior walls and ceilings and can be used for less demanding and lower cost exterior structures (such as warehouses)
    • Maximum operating temperature: 90 o C
    • Minimum working temperature: 0 o C
    • Minimum operating temperature -60 o C
  • Polyester matt
    • Thickness 35 µm
    • G ood UV and corrosion resistance
    • Special feature of this coating is its matt-like finish
    • Colours suitable for roofing products
    • Typical applications include tile sheets and profiled sheets. It is especially suitable for new residential buildings and renovations
    • Maximum operating temperature: 90 o C
    • Minimum working temperature: 0 o C
    • Minimum operating temperature -60 o C
  • Pural
    • Thickness 50 µm
    • Polyurethane-based coating with polyamide
    • Excellent corrosion resistance
    • Very good UV resistance
    • Very good plasticity
    • Recommended especially for roofings where especially good weather resistance is required. It is also suitable for rain water systems
    • Maximum operating temperature: 100 o C
    • Minimum working temperature: -15 o C
    • Minimum operating temperature -60 o C
  • Pural matt
    • Thickness 50 µm
    • Polyurethane-based coating with polyamide
    • Special feature of this coating is its matt-like finish
    • Excellent corrosion resistance
    • Very good UV resistance and plasticity
    • Pural matt is recommended to use in roofings, where very good resistance to weather conditions is required
    • Maximum operating temperature: 100 o C
    • Minimum working temperature: -15 o C
    • Minimum operating temperature -60 o C
  • PVDF
    • Thickness 27 µm
    • Metallic colours also (silver, dark silver, etc.)
    • Good resistance to corrosion
    • Very good plasticity
    • Excellent resistance to UV-radiation
    • Excellent characteristics to keep itself clean
    • PVDF is recommended to use in claddings, where exceptionally good weather and external appearance qualities are needed. Excellent for other sheet claddings and copings also
    • Maximum operating temperature: 110 o C
    • Minimum working temperature: -10 o C
    • Minimum operating temperature -60 o C
  • PVDF matt (new product 2009)
    • Thickness 27µm with matt-like surface
    • Metallic colours also (silver, dark silver, etc.)
    • Good resistance to corrosion
    • Very good plasticity
    • Excellent resistance to UV-radiation
    • Excellent characteristics to keep itself clean
    • PVDF is recommended to use in claddings, where exceptionally good weather and external appearance qualities are needed. Excellent for other sheet claddings and copings also
    • Maximum operating temperature: 110 o C
    • Minimum working temperature: -10 o C
    • Minimum operating temperature -60 o C
  • PVC Laminate
    • Food safe laminate (120µm)
    • Fire resistant laminate (150µm)
    • Excellent washability and corrosion resistance (due to primer)
    • Maximum operating temperature: +60 o C
    • Minimum working temperature: +10 o C
    • Minimum operating temperature -40 o C
  • Purex TM
    • Nominal thickness of coating 26 µm
    • Top coating 20 µm and primer 6 µm
    • Slightly structured surface
    • Excellent appearance
    • Resistance to atmosphere stresses
    • Good forming properties
    • Very good resistance against UV-radiation, corrosion and dirt pick up
    • Highest operating temperature: 100 ºC
    • Lowest operating temperature: -60 ºC
    • Lowest forming temperature: -15 ºC
    • A totally new coating developed by Ruukki especially for roofing applications
  • PVDF coating
  • PVDF
    • Normal colour coating
    • Suitable for all steel façade product applications
  • PVDF matt
    • New coating PVDF matt for facades and its properties
    • Developed to specifically meet modern architectural demand and trends
    • Normal colour coating
    • Suitable for all steel façade product applications
  • PVDF HB
    • Thicker than normal colour coating
    • Recommended for applications in severe corrosion conditions such as marine or industrial climates
    • Suitable for all steel façade products applications
  • PVDF HB+L
    • Thicker than normal colour coating + clear lac
    • Recommended for applications in very severe corrosion conditions such as tropical or sub-tropical areas and difficult industrial climates
    • Suitable for all steel façade products applications
  • PVDF METALLIC
    • Metallic, lustrous, normal thickness colour coating (PVDF Metallic HB and PVDF Metallic HB+ L are also available)
    • Recommended for applications in which a metallic, light reflecting appearance is desired
    • Suitable for all steel façade products applications
  • Maintenance
    • You need to paint carefully to the scratch! Use Ruukki’s repairing paints
    • Painting with aerosol products is prohibited:
      • Resistance to corrosion is weak
      • Resistance to UV radiation is weak
      • Colour changes quickly
  • Maintenance
    • Grinding machine is strictly forbidden in every case!
      • If used, guarantee is immediately no longer valid
      • Coating burns off and falls away from the cutting point
      • Hot metal pieces melt into the coating and start to rust
    • Also thinner discs damage the coating as well
    • Use only tools that doesn’t warm up:
      • Circular saw with hard metal tip and negative angle (cut from the back side of the sheet)
      • Handsaw with metal blade
      • Nibbler (can be used from both sides)
  •