Perspective

Colour coated sheets industry in India: An overview

T

- Sanjay Sengupta

he Indian producers of colour coated steel have introduced state-ofthe-art technology and are capable of producing high quality material in a cost-effective and eco-friendly manner. They should seriously consider the switchover to the use of chromate-free processes in pre-treatment and coil coating paints. With construction and domestic appliances set to post robust growths in future, the Indian colour coated steel industry is expected to record a much better performance in the next few years

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Perspective
Steel is a versatile material. The unique position of steel remains unchallenged even today and life without iron and steel remains almost unimaginable. Steel has a wide range of applications from the manufacturing a small pen to automobile, railway system, aircraft for both civil and military operations, big engineering and construction projects, nuclear power stations, generation of power, housing, port construction, irrigation projects and so on. During the last three decades or so, the world has seen many innovations in the process of steelmaking and vast technological up-gradation to make steel competitive. Steel producers all over the world are giving major thrust on value addition to produce superior quality of products in a cost effective and eco-friendly manner. Both long and flat steel products have undergone remarkable orientation in product mix to suit high end applications conforming to very stringent specifications as required by the demanding end-users. In the flat product segment, galvanised steel in India has seen many new applications in sectors like construction (including housing), automobile, consumer durables etc. One of the most remarkable achievements in the Indian galvanised steel industry has been the development of colour coated sheets.

Colour Coated Sheets

Colour coating usually refers to the application of liquid paint coat over the substrate in an automatic continuous process after pretreatment. The preprinted colour coated steel is a very high value-added product that combines the best properties of the substrates and organic coating additionally, imparting it an aesthetic finish, high degree of durability and high corrosion resistance capability.

building facades, washing machines and other white goods. Coatings provide corrosion resistance, colour and surface texture. Once the metal strip has been coated, the panels are cut, shaped and fitted, which after involves high complex processing stages such as deep drawing and roll forming. The coating surfaces should be able to withstand mechanical damage, heat chemicals and moisture. For instance, a building has to withstand the adverse effects of wind, rain and sun attack and in the white goods sector, surfaces are exposed to variety of abuses during use. Besides the above, there is a multiplicity of applications for coil coated materials. For each material and each step in the various production stages, there is an acknowledged state-of-the-art, which represents current knowledge about the material and its processing.

During the last three decades or so, the world has seen many innovations in the process of steelmaking and vast technological up-gradation to make steel competitive

Colour
The construction industry and white goods manufacturers have followed the carmakers' trend towards metallic colours for many years. While historically these colours were only available in polyester, polyurethane or polyvinylidene fluoride (PVDF) topcoats, a special formulation process now permits brilliant metallic colours also to be provided for polyvinylchloride (PVC) plastisols.

Basics of Coil Coating

Coil coatings, the continuous coating of aluminium and steel coils, is a step in the manufacture of industrial semi-finished products for use in

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treated surface. The primer provides flexibility to the paint system and helps corrosion resistance to a great extent since it contains corrosion inhibitors. The primer is cured in the oven with temperature control with great precision. Various types of primers are available based on different resins like epoxy, polyester, polyurethane and PVC. Epoxy primers are preferred for use in roofing as it contains chromate pigment for better.

Substrates
Colour coating is done on various substrates to produce the most cost effective, quality assured products with top coat compatible with environment. The substrates usually used are: l hot dipper galvanised steel l electro-galvanised steel l Galvalume l Galbosheets l Aluminium For selecting the right kind of substrate, it is imperative to know that each material used and each step taken in various production stages. The producer should possess a thorough and in-depth knowledge about the material and its processing.

Chromate Coating and Chromate - free Coil Coating

Historically, chromium compounds have been the key anti-corrosive agents in coil coating paints and pretreatment. Normally, a two coat system consisting of a top coat and a primer is applied to pretreated metal substrate. The vast majority of traditional coil coating primers contains chromium compounds such as strontium and zinc chromate to achieve the necessary corrosion resistance of the final product. Hexavalent chromium compounds (Chromium VI) serve as an electro-chemical coupler that can inhibit corrosive reactions on most surfaces. However, hexavalent chromium compounds widely used in industrial metal coatings are classified as carcinogens (category 1 & 2) as well as being toxic and dangerous to environment by Dangerous Substances Directive by EEC, 9th Amendment, 28th adaptation to technical progress. It is true that once the pigments are embedded in the paint film, there are no imminent health hazards. But in considering the risks associated with production of the materials at each stage of their life and each process has to be taken into account.

Major producers of colour coated sheets in India have introduced No-Rinse technology in place of phospating (phosphate coating) over the galvanised strip because of better bath maintenance, uniform clear structure of coating

Pretreatment
Pretreatment of the substrate is a very important operation required for better adhesion formability of the preprinted steel sheets. Major producers of colour coated sheets in India have introduced No-Rinse technology in place of phospating (phosphate coating) over the galvanised strip because of better bath maintenance, uniform clear structure of coating as well as to meet the demands of end-users for more flexibility of coated sheet. No-Rinse coating pre-treatment is a very thin layer of chemical treatment that bonds the coating surface of steel to the subsequently applied point to ensure excellent point adhesion, corrosion resistance and durability of steel substrate.

The Alternative
Under its sustainable development and responsible care programme, BASF Coatings started to explore options for replacing toxic chromate pigments in the early 1980s. It was clear from the start that an alternative to chromate containing primers had not only to be chromate-free but had to

Primer
After pre-treatment, the primer of uniform layer is applied on the pre-

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match or surpass the overall performance of its chromatecontaining rivals. By the middle of 1980s, these requirements were met for household appliances, as weathering and corrosion-resistant demands of the indoor applications are less stringent than for outdoor panels. By 1992, the first generation universal chromate-free primers for exterior applications were introduced and in 1995, there was a further decisive breakthrough; BASF's chromate-free universal primer on galvanised steel surfaces gave superior results over both chromatefree and chromate-containing pretreated coal. Continuous adaptation and optimization during the subsequent years led to further improvements. The main resin system of chromate-free primers consists of a mixture of high molecular weight polyester and epoxy resins, crosslinked in a system based on amino resins. The pigment is also not only chromate-free but also for free of any other heavy metal or carcinogenic materials. According to experts, the construction industry is somewhat conservative and will need to have confirmation of the benefits and long life performance advantages of using chromate-free coatings. There will be a clear advantage for coil-coaters that make the switchover and establish a clear track record with the technology of chromate-free coil coatings. plastisols for cost effectiveness and durability.

Benefits of Paint Coating on Galvanised Steel

When paint and galvanised steel are used together, the corrosion control provided is superior to either system used alone. The galvanised coating protects the base steel, supplying cathodic and barrier protection and the paint slows down the rate at which the zinc is consumed greatly extending the life of the galvanised steel. Once the paint has weathered down or damaged, the zinc is available to provide cathodic and barrier protection to avoid rust after paint peels off. Because of this synergistic effect for a duplex coating, it provides corrosion protection 1.5 to 2.5 times longer than the sum of the lifetimes of zinc and paint used individually. For example if the galvanised coating life on steel is expected to be 15 years and the paint coating life on steel is expected to be five years, the galvanising and paint when used together, gives a life of 35 years, which is 1.7 times the sum of both systems used individually.

The main resin system of chromate-free primers consists of a mixture of high molecular weight polyester and epoxy resins, cross-linked in a system based on amino resins

Textured Surface
The topography of the coating

Topcoat
After pre-treatment, the primer surface is coated at uniformly coated thickness and then cured in the oven. The top coat contains a combination of colour pigments and additives which provide the required colour of the colour-coated sheets and infuse other properties like ultraviolet resistance. The coated product is then rigorously tested before clearing for further applications. Most of the roofing and construction markets for colour coated sheets use top coats which are based on polyester, polyvinylidene fluoride (PVDF), silicon modified polyester (SMP) and

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surface is a significant design element. Roll application of coating actually results in a smooth surface in the coil coating process. Thus when in 1980s, the white goods inducting began using pre-coated panels in combination with sprayed components, there was a mismatch in surface appearances. The coating process was required to look as if it had been painted using spray application including the typical orange peel effect. The challenge was met by the introduction of special texture primer which was over-coated with a top coat adapted to the primers. However, enormous efforts were needed initially to achieve reproducible texture, but the innovation that was launched as a result became established by mid-1990s and now represents the coil coating standard not only in Europe but in other industrialized countries of the world. In addition to its design aspects, the textured coil surface offers advantages in processing. The friction properties in dies are lower than those of a conventional smooth coating. Also the surface is more robust and not so easily damaged during the assembly process and unevenness and flaws are masked by the texture. Ultimately, the surface requires less care by the consumer. The advantages in the processing of textured coil surfaces can also be exploited with textures produced in other ways. Their appearance is different, but they are easier to process and the more wear resistant than smooth surfaces. For example, polyamide in a fine particle distribution can be incorporated into the colouring topcoat. Roller blind elements very often use a surface of this kind where the flexible polyamide particles ensure enhanced wear resistance for the coating to cope with the frequent opening and closing of the roller blinds.

The coating process was required to look as if it had been painted using spray application including the typical orange peel effect.

Colour Coated Steel Industry in India

India was a late starter in colour coating business. The present structure of the industry is as follows:

A : Number of units : 7
Number of working units: 7 Estimated capacity: 800,000 tonnes Estimated production in 2009-10: 680.000 tonnes
Consumption Pattern Construction sector Including buildings Domestic appliances Including white goods Others TOTAL (%) 40 55 5 100

B. Domestic Demand
The domestic demand for colour coated sheets in India is steadily increasing over the years. The estimated demand in 2005-06 was 85,000 tonnes which has gradually increased to 215,000 tonnes in 200910. The details are furnished below year-wise:

Domestic Demand of Colour Coated Sheets In India

Year 2005-06 2006-07 2007-08 2008-09 2009-10(e) (e) = estimated Domestic Demand ('000 tonnes) 85 110 140 175 215 Y-O-Y growth (%) 29.41 27.27 25.00 22.86

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Producers of Colour Coated Sheets in India
Originally, Ispat Industries Ltd and Shree Precoated Steels Ltd (SPSL) were the only two producers of colour coated sheets in India, each having a capacity of 50,000tpy. At present Ispat's capacity is being expanded to 100,000tpy. SPSL, which has since been acquired by Essar Steel Ltd, has a present capacity of 400,000 tpy of its colour coating line. Bhushan Steel and Strips has commissioned a 120,000tpy capacity colour coating line at Khopoli in Maharashtra. Tata Bluescope joint venture on 50:50 basis has installed a metallic and colour coating and painting facility at a metallic and colour coating and painting facility at Bara near Jamshedpur in Jharkhand with a capacity of 25,000 tpy of premium zinc and aluminium coated material called Zincalume (also called Galvalume) and pre-painted zinc and aluminium coated steel called COLORBOND whose capacity is 150,000 tpy. Uttam Galva Steels Ltd has set up 80,000 tpy capacity colour coating line at Khopoli (Maharashtra). Steel Corporation of Gujarat Ltd, now owned by Essar Steel Ltd, has set up a new colour coating line with a capacity of 50,000 tpy. Jindal Iron & Steel Co (JISCO) is setting up a colour coating with an annual capacity of 1,00,000 tonnes at Tarapore. carrousel coiler. Bokaro's new CR mill will have a most modern colour coating line of 50,000 tpy capacity initially.

Conclusion
Colour coated sheets are high valueadded products that combines the best properties of the substrates and organic coating additionally importing it an aesthetic finish, high level of durability and stiff corrosion resistance. While selecting a substrate, the producers are required to know the basic characteristics of the material to be used. Textured coil surfaces provide advantages in processing of the coil. The surface is more robust and not so easily damaged during the assembly process. The Indian producers of colour coated steel have introduced state-ofthe-art technology and are capable of producing high quality material in a cost-effective and eco-friendly manner. They should seriously consider the switchover to the use of chromate-free processes in pretreatment and coil coating paints. With construction and domestic appliances set to post robust growths in future, the Indian colour coated steel industry is expected to record a much better performance in the next few years. With pre-fab construction trend becoming increasingly popular in India colour coated steel demand has improved significantly. The user industries find these sheets more ecofriendly.
Acknowledgments 1.`Innovative surface design with coil coating' by Lother Sandel of BASF, published in Millennium Steel 2006. 2.Article in `Steel Times International,' January 2005 issue on chromate-free coil coating process. 3.Various articles by L Pugazhenthy, ED, ILZDA 4.Article by G D Patange, Former GM, Uttam Galva Steels Ltd, in `Steelworld' in January 2009 issue

Textured coil surfaces provide advantages in processing of the coil. The surface is more robust and not so easily damaged during the assembly process.

In the Pipeline Bokaro Steel Ltd's New Cold Roll Mill

Among the features of Siemens VAI for the major portion of the new 1.3 mtpy capacity cold rolling mill coming up in SAIL's Bokaro Steel plant at Jharkhand are Siroll CIS CM and PL product line. The first link of the production chain will be in tandem with cold mill coupled to a pickling line. The state-of-the-art PLTCM will be first of its kind in India equipped with heavy gauge laser welder (LW 2 IH) pickling section, horizontal looper and side trimmer; 5 and 6 High cold mill and a

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