POWDER COATING - surface & design

Powder coating

Powder coatings, also called stove enamel finishes, adhere excellently to the substrate. They may be milled and offer both a high chemical and thermal resistance.

Electrostatic polyester resins are sprayed on electrically grounded parts by means of compressed air. Electrostatic attraction makes a pre-defined amount of powder adhere to the component. In the smelting furnace the polyester resin is reduced into a fluid state and forms a continuous polyester resin film which is characterized by its high resistance against weathering and mechanical stress.
Electrostatic powder coatings represent an environmentally sound technique as they do completely forego the use of solvents and are characterized by a highly efficient recovery of residual powder (about 98 %).

Potential component size:
length 7000 mm x width 800 mm x height 2000 mm

Powder coating RAL Standard colors

RAL standard colours are available at short notice from our warehouse. With 75% ±10% the gloss level is that of silk gloss. Compared to high-gloss surface finishes they show a considerably higher resistance against mars and weathering phenomena.

Please ask for specimen or samples!

Here you can find our online colour chart with RAL - colours available from stock.

Special - powder coatings

Besides RAL standard colours there is a whole range of special-effect powder coatings. The developments in this field open up an even greater offer of colours and possibilities. Depending on the powder composition a huge variety of effects can be achieved. Almost unlimited aesthetic possibilities are thus offered from matt to high gloss, from fine to coarse textures and from metallic to glitter coatings. Please contact us for further information on indoor or outdoor applications, prices, orders, delivery times etc.

Please ask for specimen or samples!

Colour chart with fine texture & metallic colours.

High quality powder coating

Our standard quality is perfectly suited for aplications with normal environmental and weather conditions with standard UV-radiation. For special requirements with high UV- and weathering resistance we recommend the use of high weather resistant powder qualities HWFclassic or HWFsuperior. All HWF powders include the DURA®clean technology with dirt-repellent finishing features.

GSB + Qualicoat

Especially in architecture, durable, sustainable solutions play a crucial role. To provide building owners, metalworkers, and architects with maximum assurance, we produce our powder coatings according to international standards, ensuring quality control. We undergo testing by GSB and Qualicoat to guarantee this. The German Association for Quality Assurance of Powder Coatings (GSB) awards us the GSB-MASTER certificate upon successful completion of the testing. In 2021, we also had our powder coating quality tested by Qualicoat to ensure compliance with the Qualicoat Seaside Standards.

Qualicoat Seaside

When it comes to corrosion protection, ALUTECTA customers have always been on the safe side. Since 2021, the Qualicoat Seaside seal of approval confirms that our powder coatings meet Seaside standards. This gives our customers the assurance that their powder-coated surfaces are protected against environmental influences and can be used under harsh environmental conditions. Pre-anodized powder coatings with highly weather-resistant powders provide optimal corrosion protection, for example, in coastal areas.

Pre-anodisation

Besides the use of high-quality powders, pretreatment and the creation of the conversion coating are crucial for surface adhesion. Pre-anodised coatings offer the highest possible protection against corrosion and are suitable even for extreme environmental conditions, such as highly saline air. Pre-anodisation is a special anodizing process for creating a conversion coating. Just like all anodized surfaces, the pre-anodised layer is firmly anchored in the base material. The uncompacted anodised pores provide an excellent base for the subsequent powder coating.

Pretreatment

The prerequisite for a durable protection and beautiful appearance of coated metal surfaces is their appropriate pretreatment. Adhesion-reducing impurities (e.g. rolling oils) are detached by degreasing and etching and the natural oxide layer is removed.

In a second procedural step a new layer will be applied, generally a yellow chromate or anodising layer. This very thin chromate or anodising layer conveys excellent adhesion properties to the coating and passivates the metal surface (see ill.). The passivation along the metal edges and of spots with deep defects in the coating film that reach down to the metal surface prevents furthermore corrosion-creep in the coating.

Between the operations the material is thoroughly rinsed. The last pretreatment step consists in the drying of the coating in the convection oven.

Powder coating the process

Subsequent to a 100% drying of the chromate layer the polyester resin is electrostatically charged in a closed booth and is sprayed on electrically grounded parts by means of compressed air. Residual powder is recovered and recirculated.

Aluminium surface with coating

At a baking-in temperature of about 180°C the powder begins to smelt in a first step while fixing within the chromate film and a crosslinking reaction occurs. As a result, a continuous and firmly adhesive polyester resin film emerges, which is characterized by a high weathering resistance and shows good mechanical properties (see ill.). The film thickness is of 60 µm - 120 µm (as specified by the manufacturer of the coating powder).

Properties

The powder coating has excellent adhesion to the substrate, can be machined, and has both high chemical and thermal resistance.

For outdoor powder coating applications we use high-end polyester resins that perfectly meet the demands of weathering exposure (see quality, GSB and Qualicoat Seaside). Appearance and applications of the powder coating may be adjusted by the use of the respective formulation.

Powder coated aluminium products may be milled and the powder coating offers a high chemical and thermal resistance.

Powder coated metal components combine high functionality, an aesthetic appearance, protection and low maintenance. A broad offer of shades and textures provides you countless possibilities to design surfaces and thus design the appearance of the idea you put in aluminium or steel.

Guidelines

Guidelines for Practical Collaboration in Powder Coating.

Knowledge of the technical possibilities and requirements for working with aluminum is the foundation for optimal quality. Therefore, we would like to share our experience with you. Below you will find the most important points that can serve as planning aids for your production.

Hinweise für die praktische Zusammenarbeit bei Pulverbeschichtung

• Gloss Level - If no specification is given, we supply a gloss level of approximately 75%, measured at an angle of incidence of 60° according to ISO 2813.
• Contact Points - An important prerequisite for quality. For profiles, we require 5 cm per end; depending on the cross-section, additional contact points in the center of the profile are necessary. For sheets, bent parts, and other components, mark permissible areas for contact points.
• Prerequisite Material - The surface must be flat, mill-finished (as extruded or rolled), and free of corrosion and contaminants such as adhesives, paints, felt-tip pens, resinous oils, adhesive tape residue, and especially silicones. Unevenness may be visually accentuated by the coating!
• Plastic webs of insulating profiles must be suitable for a melting temperature of 180°C for a duration of 20 minutes.
• Welded seams should be ground flat before coating. Screw, rivet, and folded connections, etc., should be made after coating (blistering or crevice corrosion is possible).
• Frames made of hollow chamber profiles must have sufficiently large holes at the top and bottom for the inflow and outflow of the treatment fluids. If necessary, we can drill the holes for a fee. The selection of the drilling locations is based on our experience.
• Threads, mating surfaces, screws, rivets, etc., which must not be chemically attacked or coated, can be protected appropriately.
• Variations in color, gloss level, and texture can occur if surfaces from different manufacturers are used without specific coordination.
• Screw, rivet, and folded connections, etc., should be made after coating.

Powder Quality

Standard Quality

Our standard quality is a weather-resistant polyester powder, ideally suited for all applications with normal technical and high optical requirements.

The standard quality is particularly suitable for normal UV exposure, meeting the quality guidelines of GSB, Qualicoat, and Qualicoat Seaside, as well as AAMA 2603-05, equivalent to one year of Florida outdoor weathering.
Based on saturated polyester resins, the corresponding hardener, and special heat-, light-, and chalking-resistant pigments.

Properties

• Excellent light and weather resistance
• Impact-resistant surface with a smooth finish
• Good elasticity, etc.
• Non-yellowing in directly heated gas ovens

Applications

• Facade elements, window profiles
• Bicycle frames
• Agricultural machinery
• Garden and camping furniture
• Vending machine housings, control cabinets
• Lighting fixtures
• Railing components

The standard range is available in a wide range of colors with varying gloss levels and textures.

Surface characteristics, gloss levels

• Series 5603 - corresponds to matte, smooth, 25 – 35,R ’/60 °
• Series 5607 - corresponds Silky sheen, smooth, 65 – 85,R ’/60 °
• Series 5809 - corresponds Gloss, smooth, 85 – 100,R ’/60 °
• Series 561M - corresponds Matt, fine structure
• Series 591T - corresponds deep matt fine structure

HWFclassic

High weather resistant Powder HWF classic (formerly known as HWF 3001)HWF classic has been developed for high-end applications.
HWF classic HochWetterFest, for facades, with high UV and weathering resistance

HWF classic is available in an expanded range of HWF colors in gloss, satin, matt as well as translucent finishes.

All HWF coatings are equipped with the DURA®clean technique.

HWF classic performance data

• 10 year warranty on color stability and residual gloss according to the standards AAMA 605.2-92, Qualicoat standard cl. 2
• Emmaqua results according to ASTM-G 90-91, proc.B
• 3 years Florida exposure according to ISO 2810
• solvent-free, unproblematic disposal as compared to fluoropolymers
• more than 1.000.000 m2 powder coated reference objects worldwide
• exempt from labelling
• no highly toxic substances such as e.g. fluorinated hydrocarbons are released in case of fire
• can be repaired
• convenient baking temperatures from 180 °C

Application fields: Large-scale constructions; buildings in locations with extreme climatic conditions; high-rise buildings; etc.

Surface characteristics, gloss levels

• HWF 5909, gloss, 85 – 100,R '/60 °
• HWF 5907, silk gloss, 65 – 85,R '/60 °
• HWF 5903, matt, 25 – 35,R '/60 °
• glitter pearl effect

Available colors

• about 100 RAL-shades
• about 700 NCS-S- shades
• glitter pearl shades (single coat)
• various color gradings based on specimen

Special applications
In seashore areas we recommend the application of 2 coats as follows:

• base coat Korroprimer
• top coat HWFclassic

Bright silver effects with system authorization Qualicoat P-0481

• base coat HWF 5903D
• clear lacquer HWF 5903B

HWF superior

High weathering resistant Powder HWF superior is a quality-certified coating powder for very high demands placed on the weathering resistance for the commercial sector based on saturated poly- ester resin and declaration-free hardener.

Surface appearance

• 5707A, smooth finish, silk gloss with DURA^®clean effect
• 5707E, pearl mica effect, silk gloss with DURA^®clean effect
  Gloss level, ISO 2813: 65 - 85 R'/60°
• 5703A, smooth finish, matt with DURA^®clean effect
• 5703E, pearl mica effect, matt with DURA^®clean effect
  Gloss level, ISO 2813: 25-35 R'/60°
• 571TA, fine structure, deep-matt
• 571TE, fine structure, deep-matt with pearl mica effect

Characteristics / application

• Architecture elements such as: facades and window profiles
• Industrial structural elements and objects for use outdoors
• Infrastructure facilities

The coatings have good mechanical values and high resistance to chemicals. High UV resistance, slower film degradation and the dirt-repelling properties of the film surface allow much longer intervals between facade cleaning operations.

By adding the DURA^®clean- effect the HWFsuperior products possess a surface which can be cleaned eysily.

Deep-matt powder DURA^®xal

The DURA^®xal surface replicates the velvety look of a matte metal. The elegant surface is characterized by excellent light and weather resistance and is suitable for both indoor and outdoor use. All DURA®xal products incorporate DURA®clean technology.

DURA®xal 4201 is a new generation of dull matt, highly weather-resistant coating powders based on acrylic-copolymer resins, with corresponding hardener combinations and heat, light and chalking-resistant pigments.

DURA®xal 4201 is the product of many years of IGP development for the optimi- sed presentation of eloxal colours and dull matt, distinguished surfaces for the industrial and high-quality design sector. At the same time, the innovative bonding agent combi- nation permits outstanding gloss retention, excellent coating characteristics and good resistance to both chemicals.

Characteristics

• Outstanding light and weather resistance
• Dull matt surface
• Eloxal effect look
• Excellent coating characteristics
  
  

Area of application

• Façade elements
• Window profiles
• Design elements
• High-quality office furniture
  
  

Surface aspects

• 4201A, smooth finish, dull matt
• 4201E, pearl mica effect, dull matt
• 4201H, crystal-color, dull matt
  gloss level, DIN EN ISO 2813: < 12 R'/60°

Surface aspects

• 4601A, smooth finish, dull matt
• 4601E, pearl mica effect, dull matt
  gloss level, DIN EN ISO 2813: < 12 R'/60°

DURA^®clean

DURA^®clean – the technical effect
Coatings equipped with DURA^®clean possess a hydrophobic surface thanks to a highly effective admixture. Dirt particles cannot easily adhere to the coating's surface and are beaded away by water. The additives used are distributed throughout the coating's structure and have a permanent effect, in contrast to a subsequent (temporary) application of preservatives. This improved dirt-repellence requires fewer cleaning interventions and implies lower maintenance costs in general. Moreover, the costs for each individual cleaning intervention are reduced all the same.

The robust effect
Coatings furnished with DURA^®clean withstand cleaning better and excellent results are obtained from use of non-abrasive cleaning with sponges and water.

DURA ^®clean is available as an optional extra in all standard qualities of the whole range of colors.
Additives are integrated during powder production. All HWF powders are equipped with the DURA ^®clean technique.

A = non hydrophobic surface
B = hydrophobic surface with DURA^®clean effect

UniversAL Powder coating cleaner + Repairs

UniversAL Cleaner provides cleaning & protection for powder coated surfaces. It can be applied on elements with smooth coloured varnish or structured and metallic finishes. The UniversAL cleaner is a special product for the maintenance and the protection and of powder coated architecture elements. The ingredients combine care components, solvents and preserving agents. UniversAL also protects surfaces from weather effects and environmental pollutants. There are no polishing agents or silicon compounds or aromatic hydrocarbons. UniversAL Cleaning & Protection for powder-coated or further coated / anodised aluminium surfaces comes in a set with a 100 ml bottle plus cleaning cloth or in a 500 ml bottle.

Minor imperfections and scratches can be repaired with a suitable paint. Touch-up pens and spray cans compatible with our powder coating are available from us. Larger areas of damage can only be repaired by recoating.