METALCOLOUR
TECHNICAL SPECIFICATIONS
July 2010
PAINTED STEEL
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Contents
Foreword ...................................................................................3
Steel ...........................................................................................4
Lacquer ..................................................................................... 5
Protective foil (Film) .................................................................6
Coils/Slitting .............................................................................. 7
Embossing .................................................................................8
Plates/Format cutting .............................................................9
Packaging .............................................................................. 10
Quality control ....................................................................... 11
Checklist ................................................................................. 12
Capability ............................................................................... 13
Tolerances............................................................................... 14
Characteristics ....................................................................... 15
Squareness ............................................................................. 16
Camber ................................................................................... 17
Flatness .................................................................................... 18
Basis of agreement ................................................................ 19
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Foreword
The ever-increasing number of workplace and environmental regulations
are leading more and more manufacturers in the metal industry to decommission their own paint-finishing facilities
in favour of pre-finished coiled sheet
steel.
At Metalcolour, we are intensely focused on environmentally and chromefree production. All waste water from
production is discharged into our own
waste water treatment plant and other
waste products are sent to approved incineration facilities.
Working practices of the past, such as
cleaning in-house paint finishing facilities when changing colours as well
as the use of painting booths with employees in space suits are simply being
replaced by modern high-tech and
environmentally-friendly
pre-finishing
facilities.
The air from the coating line is vented
directly to a high-temperature incinerator so that any unpleasant odours are
eliminated the treated ventilation air is
released back into the environment.
One of the benefits of this includes considerable energy savings, fewer working
procedures in the manufacturing process and greater freedom when it comes
to choosing finishes according to the
product's specific field of application,
even before the product is manufactured.
All in all, pre-finishing and a reduction in
manufacturing processes results in a significant reduction in CO2 emissions.
The environment and targets for a clean
environment
To Metalcolour, these are not simply
empty words. The more efficiently a company operates, the better equipped it is
to keep abreast of environmental considerations.
Our environmental consciousness starts
with a good working environment for
our employees, the personal commitment of the individual and lastly – but
not least – close cooperation with our
customers and suppliers.
Quality
”Quality is when it is the customer that
comes back – not the product.”
At Metalcolour, we constantly strive towards developing our quality to live up
to the ever-increasing demands of our
customers.
As a DS/EN ISO 9001: 2000 certified company, we are able to document quality
right from the sub-supplier to delivery of
the finished product.
Through an uncompromising approach
to the management of quality and delivery times, Metalcolour contributes to
ensuring an optimal production flow for
our customers.
Kim Højvod
Quality manager
Metalcolour 2009
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STEEL
Metalcolour takes an uncompromising
approach to delivery of the specified
quality. As an example, we test every
single coil to ensure it is the correct colour and has the required bend properties before it leaves our factory.
Finishing requirements can vary greatly
from sector to sector. These may relate
to technical specifications, the quality
of the steel itself, mechanical characteristics, the type of coating, its properties
and/or special colour requirements. All
of these are adjusted after close cooperation with the customer following meticulous analyses.
The products can be manufactured
in cold-rolled steel as well as hot-galvanised steel, aluminium and stainless
steel, in thicknesses ranging from 0.4 mm
to 1.25 mm. The maximum width is 850
mm.
Production is carried out in a continual
process whereby coils of unprocessed
steel undergo various treatment processes that clean and prepare the steel
prior to final lacquering or laminating.
COATERLINE
9
10
Throughout the process, automatic
checks are carried out on, for instance,
colour and thickness using methods
developed by the industry association
ECCA (European Coil Coating Association).
Finally, the steel is rolled into a finished,
surface-treated coil which can then be
slit into rings or cut into format plates to
match most production requirements.
Coils can be supplied with a wide variety of surface coatings, for example,
laminate of various types and differing
patterns. With smooth or embossed
Plastisol coatings. In matt or high-sheen
polyester, or with polyurethane lacquer
in countless colours.
All our production is carried out in accordance with European standards:
EN 10 142
EN 10 143
EN 10 147
EN 10 169
EN 13 523
11 12
20
15
3
1
2
5
4
6
8
7
1 Uncoiling
2 Accumulation
3 Cleaning
4 Brushing
5 Cleaning
6 Rinsing
7 Pasivation
8 Drying
9 Primer coating
10 Drying
11Air cooling
4
13
17
14
16
12 Water cooling
13 Finish coating
14 Drying
15 Foil
16 Laminating
17 Water cooling
18 Air cooling
19 Accumulation
20 Protective foil
21 Recoiling
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19
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LACQUER/SURFACE
Metalcolour’s product range encompasses total deliveries of coil-coated
sheet steel in dimensions of a maximum
of 850 mm and thicknesses up to a maximum of 1.25mm. We offer a wide range
of finishes and are happy to undertake
special ”one-off” assignments.
Coated on both sides
TOPCOAT
PRIMER
ZINK
PRE-TREATMENT
STEEL
Coated on one side
TOPCOAT
PRIMER
PRE-TREATMENT
ZINK
STEEL
BACKING COAT
ZINK
STEEL
BACKING COAT
Laminated
LAMINATE
ADHESIVE
PRE-TREATMENT
The production methods used by Metalcolour result in products of a higher
quality than would be obtained using
traditional surface treatment methods.
Metalcolour’s sheet steel has great
plasticity, excellent durability and low
weight, and is therefore able to with-
stand any subsequent profiling, edge
modification, perforation, punching
and scoring.
Thanks to our know-how and flexibility,
we are able to offer a wide range of
finishes and thus accommodate the individual requirements of individual customers. These may relate to technical
specifications, the quality of the steel
itself, mechanical characteristics, the
type of coating, its properties and/or
special colour requirements. All of these
are adjusted following close consultation with the customer via meticulous
analyses. From that point on, and by virtue of our ISO 9001 certification, we can
always guarantee the customer the
right delivery at the right time.
We offer a wide selection of lacquering
systems and select the optimal solution
in consultation with the customer, for example:
• Polyester lacquered surfaces with high
sheen, matt or textured finishes.
• Polyurethane lacquered.
• Smooth or embossed Plastisol structures.
• Lamination of PVC foils (film) – monocoloured or patterned.
• Special surface coatings, for example,
rubber bounds
• Colours in accordance with customer
specifications.
• Sheen grades from 10 - 90.
All surface coatings are based on a
chrome-free treatment system.
LACQUER
13 523-2
THICKNESS
µm
13 523-2
GLOSS
%
13 523-3
COLORS
13 523-4
HARDNESS
13 523-5
IMPACT
RESISTANCE
13 523-6
DRAWING
%
13 523-7
ADHESION
AFTER
BENDING
POLYURETHANE
25-30µm
10-90
by colormatching
F-H
no loss
-
0 to 2T
POLYESTER
20-25µm
10-90
by colormatching
HB-H
no loss
-
0 to 3T
PLASTISOL
100-200µm
25-60
by colormatching
B
no loss
<75
0T
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PROTECTIVE FOIL (FILM)
Naturally, we can also apply protective
film to surfaces. This makes the surface
easier to handle and minimises the risk
of damage to the coated surface.
During production, in many cases, it can
be advantageous to use a self-adhesive
protective film.
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Protective film is available in a variety of
qualities, depending on needs.
We are happy to help our customers
choose the one most suited to their
needs.
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COILS/SLITTING
The coated coil can either go directly to
the customer or be slit to other widths.
The table below shows dimensions and
tolerances.
The figures shown are standard, please
contact Metalcolour if you require other
values.
SLITTING
Input material
Slit coil
max 13
-
Coil width in mm
max. 1360
min. 25
External coil diameter in mm
max. 1560
-
Internal coil diameter in mm
508/610
508
Thickness of material
in mm (steel)
min. 0,37 max.1,25
-
Coil weight in tonnes
•
•
•
Metalcolour offers slitting of both crude steel and coated materials
Width tolerance from ± 0.1 mm
NB – No cardboard cores following slitting
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EMBOSSING
Metalcolour produces moulded material that has many areas of application,
but is most often seen on gates. The
material is run through a moulding line
where it is embossed using rolls. Moulding increases the strength of the steel
plates which can subsequently be produced using up to 25% less material and
has a correspondingly lower weight.
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EMBOSSING
Width - max in mm
Internal coil diameter in mm
Thickness of material max in mm (steel)
1230
508/610
1,25
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FORMAT CUTTING
Metalcolour’s cutting line.
PLATES/FORMAT CUTTING
min.
max.
Width in mm
275
950
Length in mm
75
4000*
0,37
1,5
Thickness of material
in mm (steel)
•
•
•
•
Width tolerance from ± 0.2 mm
Length tolerance ± 0.5 at < 1 m and ± 1.0 at > 1 m
Rising height – max. 5mm
Waves – max. 2 per metre
*It is possible to cut plates measuring more than 4 metres by special order - contact us for more information.
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PACKAGING
Metalcolour offers various types of packaging. Standard examples are shown in
the sketches below.
Naturally, we offer other packaging
methods, should they be required. Contact Metalcolour’s Sales Department.
Slit rings are packed with 2 plastic bands
per ring and 2 plastic bands around the
pallet. There are 3 battens between
each ring.
Eye to sky: Coils are packed with 2 plastic bands around the pallet.
Eye to side: 1 plastic band around the
coil and 2 steel bands around the bearing. View from the front.
Eye to side: 1 plastic band around the
coil and 2 steel bands around the bearing. View from the side.
The examples shown are standard.
There can be varying needs for the way
in which the battens are applied, their
height etc.
Metalcolour’s Sales Department will go
over all the details during preparation of
the requirement specification.
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Plates are packed with tarred paper,
steel casing and 3 steel bands around
the pallet.
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QUALITY CONTROL
Metalcolour takes an uncompromising
approach to delivery of the specified
quality. As an example, we test every
single coil to ensure it is the correct colour and has the required bend properties before it leaves our factory.
Finishing requirements can vary greatly
from sector to sector. These may relate
to technical specifications, the quality
of the steel itself, mechanical characteristics, the type of coating, its properties and/or special colour requirements.
All of these are adjusted following close
consultation with the customer via meticulous analyses.
From that point on, and by virtue of our
ISO 9001 certification, we can always
guarantee the customer the right delivery at the right time.
Our certification is based on self-checking. This means that a supplier-customer
relationship exists between all employees involved in the production process... each individual employee is thus
responsible for ensuring that the product he/she hands over to the next link
in the chain has been checked and is
in order.
In addition to our ISO 9001 certification,
Metalcolour has also been brand-certified in accordance with IMO resolutions.
Moreover, we are aware of and comply
with all sector-related directives and
are happy to work out special requirement specifications in cooperation with
our customers.
In Metalcolour’s laboratory, we carry out various tests on the material during production. During these tests, checks are made on, for instance, sheen grades, adhesion, hardness, bend tests etc. Tests on all production processes are archived in
order to ensure the traceability of every order.
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CHECKLIST
Before you place an order, it is a good
idea to have some thoughts of the material wanted.
The table below gives an indication of
which information is necessary before
production.
Metalcolour's sales department will, together with the costumer, fill in a specifi cation of demands, where all issues will
be examined.
REQUIRED INFORMATION
Coils/Slitting:
Plates/Format cutting:
Packaging:
Dimension (txbxl)
Dimension (txb)
Requirements for
packaging and
labelling
Quality
Quality
Tolerances
Width and length
Flatness
Camber
Ring size
Internal and extenal
diameter
Max. length per slit ring
12
Tolerances
Width and length
Flatness
Camber
Max. diagonal divergence
Max. kilo per package/
Max. number of rings
per package
Max. kilo per package/ Max.
pieces per package/
Surface requirements
Surface requirements
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CAPABILITY
The capability of the slitting and cutting
line is as follows:
SLITTING
Input material
Slit coil
max 13
-
Coil width in mm
max. 1360
min. 22
External coil diameter in mm
max. 1560
-.
Internal coil diameter in mm
508/610
508
Thickness of material
in mm (steel)
min. 0,37 max.1,25
-
Coil weight in tonnes
•
•
•
Metalcolour offers slitting of both crude steel and coated materials
Width tolerance – min. 0.1 mm
NB – No cardboard cores following slitting
PLATES/FORMAT CUTTING
Minimum
Maximum
Thickness of material
in mm
0,37
1,5 (steel)
Width of material in
mm
275
950
Coil weight in kg
-
6500
External diameter in
mm
-
1250
Material width with
edge trim in mm
-
1046
Material width without edge trim in mm
-
900
Plate length in mm
75
4000*
Edge trim on each
side in mm
4
48
Internal diameter in
mm
508
610
Stack height incl.
Pallet in mm
-
500
Weight per pallet
in kg
-
3000
*It is possible to cut plates measuring more than 4 metres by special order - contact us for more information.
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TOLERANCES
The tolerances indicated below are best
available tolerances and for guidance
only. If other tolerances are required, it
will depend on the material and has to
be agreed on a case-by-case basis.
Length and diagonal differences are
dependent on the camber effect in the
material, over which we have no influence. However, we can halt production
if the measured value exceeds what
has been agreed.
-Read more about camber on page 17.
PLATES/FORMATCUT - tolerances i mm
LACQUER/SURFACE - tolerances
Delta E
Gloss - units
max 1
±5
SLIT RINGS - tolerances i mm
Width
14
±0,1
Width
±0,1
Length (< 1 meter)
± 0,5
Length (> 1 meter)
± 1,0
Rising height
max 5
Waves per meter
max 2
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CHARACTERISTICS
The following pages deal with squareness, camber and flatness. It is important
to take all of these parameters into
consideration before the basic material
is purchased from the steelworks.
Metalcolour’s
Sales
and
Quality
Assurance Departments are always
happy to offer advice and guidance
in order to ensure the customer is
completely satisfied.
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SQUARENESS
In the standards DS/EN 10131 (cold
rolled), DS/EN 100051 (hot rolled) and
DS/EN 10143 (galvanised), the permissible deviation from squareness is stated
as 1% of the sheet/plate width.
A
In practice, the difference between A
and B is used to measure the deviation.
See the sketch below.
Read about the camber effect on the
next page.
B
B
L
U = max
1% of
B af B
U = max
1%
Difference between A and B are not allowed to be more than 1,5 mm
Forskellen mellem A og B må ikke overstige 1,5 mm
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U
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CAMBER
Camber occurs as a result of the rolling
process at the steelworks. The camber
effect cannot be eliminated by slitting
or coil cutting the material. Camber is
present when a coil that has been rolled
out on completely flat surface is curved
in the plane.
Often, this effect is not significant but
there may be problems when it comes
to welding. If the camber effect gives
rise to problems, shearing the sides is
one option for eliminating this.
DS/EN 10143 stipulates a maximum tolerance of 5 mm, measured on a length of
2 metres. For plates shorter than 2 metres, the camber must not exceed 0.25%
of the actual length.
The sketch below shows how the tolerance is measured.
NB
A narrowed tolerance of 2 mm on a
width of <600 mm is possible by agreement. Contact Metalcolour’s Sales Department.
2000 mm
H,
B
H = max 5 mm
NB Be aware that deviations are different depending on the basic material
(whether it has been cold/hot rolled, for
example).
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FLATNESS
Tolerances for flatness are measured as
rising heights and waviness.
The rising height is the maximum distance between the plate and a completely flat base. The maximum rising
height permitted is 5 mm.
Waviness is measured from wave top
to wave top. The maximum number of
waves permitted is 2 per metre.
Wave
BØLGE
PILHØJDE
Rising
height
18
PILHØJDE
Rising
height
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BASIS OF THE AGREEMENT
Metalcolour’s Sales Department is happy to assist with advice and guidance
to ensure that the customer obtains the
most optimal solution.
It is a pre-requisite for every order that
a requirement specification is drawn up
that contains all the necessary information regarding the desired delivery.
We would like to point out that the tolerances stipulated are standard values
that can be deviated from if required.
Contact the Sales Department if you
have other requirements.
The specification deals with all the information required, right from the choice
of basic material, surface, tolerances,
testing methods, slitting/cutting to the
way in which the order is to be packaged and, if necessary, labelled.
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METALCOLOUR
Agrovej 6
DK-4800 Nykøbing F..
Tlf +45 5484 9070
Fax +45 5482 2960
CVR nr 12 65 43 91
www.metalcolour.com
P.O. Box 510
SE-372 25 Ronneby
Tlf +46 (0) 457 781 00
Fax +45 (0) 457 666 75
VAT SE556347756001