08.10.2024innovation & technology
The construction industry in India has made remarkable strides by incorporating innovative materials to enhance building components. Among these materials, precoated steel, also known as prepainted steel, has emerged as a superior alternative to traditional options for door and window frames manufacturing. To overcome the challenge, renowned coil coatings manufacturer Berger Becker India collaborated with leading prepainted steel producers.
Project overview
In India, conventional door frames made of wood or mild steel faced limitations such as termite vulnerability and susceptibility to corrosion. To address these challenges, the search for an advanced material led to the approval of precoated steel.
Project challenges
Challenges in manufacturing door frames using precoated steel arose from the thickness of the material, requiring the development of specialized coil coating paints to improve flexibility and prevent peeling. Additionally, the paint used for the door frames had to meet RoHS environmental standards, emphasizing the importance of sustainable practices. The joint efforts resulted in the development of a high-quality, flexible, and sustainable paint solution tailored to meet the specific needs of precoated steel door frame manufacturers in India.
Product overview
The door frames constructed with precoated steel, were treated with a coil coating paint system called Regular Modified Polyester, available in distinct colours such as RMP RAL 5012 and RMP Appliance White for example. Two types of coatings were developed for this application : Unicoat Topcoat (No primer) - 12 to 15µm thick topcoat applied directly without primer. Two Coats RoHS Compliance - Consisting of a 3- 5µm thickness Chrome Free Primer followed by an 18-20µm thickness topcoat. The Two Coat paint system exhibits higher corrosion resistance and excellent mechanical properties, while the Unicoat system has slightly lower corrosion resistance but still possesses good mechanical properties. Both paint systems have been well-received in the market, catering to different target market segments, namely the premium and general markets.
Solutions offered
The exceptional characteristics of precoated steel that influenced its selection for door frame manufacturing include the following:
- High Thickness Range of Steel: Precoated steel offers a thickness range of 0.6 mm to 1.8 mm, providing improved structural strength and durability for door frames.
- Exceptional Flexibility (1T/2T): The outstanding flexibility of precoated steel allows precise shaping and bending during the door frame manufacturing process, ensuring flawless profiles.
- High Scratch Resistance (Scratch hardness > 1.5 Kg) : The paint system used on precoated steel exhibits remarkable scratch-resistant properties, maintaining the aesthetics of the door frames and protecting them from wear and tear.
- Corrosion Resistance (Salt Spray >500 hrs): Precoated steel demonstrates exceptional resistance to corrosion, even in harsh environmental conditions, resulting in long-lasting performance. Developing a ROH-compliant paint system suitable for precoated steel door frames presented a significant challenge.
Additionally, operating coil coating at such high steel thickness required meticulous attention to ensure smooth operations on the color coating line.
Rigorous trials and meticulous testing validated the efficacy of the specially formulated paints in enhancing flexibility and adhesion of the precoated steel door frames. The products secured compliance with stringent quality standards and sustainability requirements, establishing their suitability for diverse construction projects.
Leading Coil Coating Steel manufacturers are delighted to have created a new market segment in the coil coating industry. They have provided a better sustainable product and solution to the door frame industry in India. Homeowners expressed delight in the durability and aesthetic appeal of their new homes' door frames. The project's adherence to sustainable practices and timely completion garnered commendation from satisfied customers.
Conclusion
This project demonstrates how technical coating development and architectural vision combine through collaborative problem-solving. The Dormagen workshop approach –bringing all stakeholders together to refine requirements and test solutions – enabled Beckers and Euramax to deliver a technically complex coating system that met both aesthetic specifications and performance requirements for a healthcare facility facade.
