Coated steel Market - Overview and Applications

Coated Steel- an Introduction 

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When the steel surface is coated with an additional layer of organic or metallic materials to protect from rusting, is called coated steel. Usually, a coating layer is added to flat steel when they are in a coil form.

Coated steel can be categorised into three broad categories: metallic coated steel, organic coated steel (non-metallic) and tinplate. Coated steel is used in applications where corrosion resistance, aesthetic appearance or food safety is essential.

Types of Coated Steel

Metallic coated steel

Metallic coated sheets are corrosion resistant steel coated typically with zinc in pure or alloyed forms. The process of zinc coating is known as &#;galvanising&#;. Most steel companies use Hot-dip galvanization (HDG) process but there are other methods depends on the required material properties.

Hot-dip galvanising is a process of coating steel with zinc or zinc alloy by putting steel in the bath of molten zinc or zinc alloy. The molten bath is prepared above the melting point of zinc or zinc alloy ranging around 820-860&#;F.

The molten bath is used with a combination of a number of surface preparation steps like caustic cleaning, rinsing, pickling, flux solution dipping and drying. The molten zinc (Zn) forms a metallurgical bond with Iron (Fe) during coating. The zinc then reacts to external oxygen and carbon dioxide to form a strong protective coating of zinc carbonates.

Electro-galvanizing is another method used for metallic coating. Electro-galvanizing produces a lower thickness of Zn or Zn alloy coatings compared to batch or continuous hot-dip galvanizing. It is also a cost-effective method for applying zinc coatings on small and intricate shapes like fasteners.

Other metallic coating methods include thermal spray (or metallising), sherardizing and thermal diffusion, mechanical plating and zinc-rich paints. These methods have nominal commercial significance in the coated steel industry.

Types of Metallic Coated Steel

• Hot-dip galvanized (HDG)

• Electrogalvanized (EG)

• Galfan

• Galvalume

• Aluminized

Organic Coated Steel

Organic coated steel is coated with non- metallic materials mostly paint. It is also known as pre-painted galvanized iron or PPGI. Substrates of the PPGI are usually the hot-dip galvanized steel. Its main applications are lifts, furniture, ceilings, decorative partitions, electronic housings etc.

PPGI are produced on continuous lines which involve a number of surface cleaning and coating steps in a controlled environment and baking at high temperature.

Paints are usually of two types. Polyester paints coatings which are used mostly in roofing and industrials sheds. Polyvinylidene fluoride paint or PVDF is another type of PPGIs.

PVDF painted sheets are expensive compared to polyester paints but gives high impact and scratch resistance. PVDF coating has a long anti-fading, anti-ultraviolet performance in harsh atmospheres. It is used in applications susceptible to high corrosion and wears and tears.

Tinplate

Tinplate is made by coating tin on the cold-rolled steel. Annealing and tempering process is used to prepare a cold-rolled sheet for tinning. The tempered steel which is used as a substrate for tinplate is called &#;black plate&#;. Tin is applied to the black plate through continues electrolytic bath. Tinplate is mainly used in food packaging applications such as food cans and drink beverages. It also has some limited applications in electrical machinery parts.

Selected Producers

Some of the selected producers in the coated steel industry:

• Arcelor Mittal

• Baosteel

• China Steel Corporation

• Essar Global

• JFE Steel

• JSW Steel

• Kobe Steel

• Nippon Steel & Sumitomo Metal Corporation (NSSMC)

• NLMK

• Nucor

• POSCO

• Severstal

• Shandong Iron & Steel Group

• Tata Steel

• ThyssenKrupp

• United States Steel (USS)

• Wuhan Iron and Steel

  See also:
  Stainless Steel Tube Supplier & Manufacturer in India

  Steelhighsen Product Page

Coated Steel Market Overview

The metallic coated steel market is driven by construction, infrastructure, automotive, engineering etc.  A galvanized roof sheet has an average life of 15 to 20 years while Galvalume has even double than that. Organic coated or PPGI demand is supported by the construction and infrastructure sectors in urban areas.

The construction sector plays a vital role as an end-user for metallic coated and organic coated steel. Growing urbanisation and rising population are developing new markets for coated steel products in the construction sector. Around 55% of the global population lives in urban areas, according to statistics of United Nation Department of Economic and Social Affairs. Urban population is expected to reach 68% by with the most increase to take place in developing markets in Asia and Africa.

The coated steel industry is dominated by metallic-coated steel which accounts for about 81% share in the total coated steel market.

New investments in the metallic and organic coated steel are being carried out mostly in Asia followed by the US. Chinese steelmaker Chengde is installing an HDG plant with 0.4 million tonnes/year capacity. JFE Meranti in Myanmar is constructing a 180k/year HDG and 90k/year PPGI plant. Both of the plants will be ready by the end of . JSW&#;s 300k tonnes PPGI plant in India is under construction and is expected to be operational by . In Pakistan, International Steels (ISL) announced capacity expansion of 350,000 tonnes of HDG and 50,000 tonnes of colour coated steel.

The US capacity for metallic and organic coated steel is also surging after the imposition of section 232. Nucor&#;s 500k tonnes/year galvanising plant was announced to be operational in . Steel Dynamics (SDI) is planning to start the construction of 450k tonnes/year galvanising line capacity with an additional paint line capacity of 250,000 tonnes per year.

North-East Asia is the largest market with ~44% share in the global metallic-coated steel consumption due to high infrastructure and construction spending and its large automotive and manufacturing industries.

Organic coated or PPGI market trends are different from the metallic-coated due to limited end-use sectors. Europe is the largest market for coated steel due to its high applications in the construction sector.

Food industry investments are mainly driving tinplate market. Regional population and food safety regulations also play an essential role in the demand for tinplate. The tinplate market is small compared to other coated steel products.  North-East Asia holds the largest share of 34% in the tinplate market, followed by Europe which accounts for 25% of global tinplate consumption.

Applications of Coated Steel

Metallic coated steel is used in applications where the material has the potential to expose to the corrosive environment during application. Zinc coating on HDG sheets acts as a protector for steel due to its high corrosion potential.

The applications include air conditioners, vehicles parts, outdoor electrical boxes, laundry appliances, refrigerators, roofing sheets, wall panels of sheds etc. HDG sheets are also used in coastal infrastructures due to its vulnerability to a salty environment.  American Institute of Architect strongly recommends the use of HDG in the 5km range of coastal areas.

Metallic coated steel applications in the automotive industry depend on the regions. There is a disparity in the use of HDG in car bodies around different parts of the world. In developed markets, there are standards which enforce the use of HDG in car panels. However, in developing regions carmakers use alternative products to cut the costs.

In India, almost 3% domestic car contains HDG while the ratio reaches around 70% in Europe, Japan and North America due to the regional regulations and warranties. These regulations and standards started emerging in the s when Japanese cars entered in the US market.

China, the largest car market, has minimal use of metallic coated steel in cars made for the domestic market. However, international brands in the country like VW and GM use the material for export-oriented cars.

Organic coated steel is used where aesthetic appearance required such as in construction and architecture. Tinplate sheets are used in the packaging sector particularly for making cans. Both organic and tinplate products account for a smaller share in the overall global coated steel coils market.

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Powder-Coated Steel vs. Aluminum

When your business works with metal products and components, you need reliable ways to make them stronger and more reliable. If you manufacture outdoor equipment like cranes or aerial platforms, you need them to be strong and resistant to any chemicals they encounter on the job. If you make metal patio furniture pieces, you need them to resist-weather related corrosion and rust while still looking stylish enough to catch consumers&#; eyes. Powder coatings offer an ideal solution.

What is powder coating, and how does it affect metals like aluminum and steel? Does powder-coated steel rust? This guide answers these questions and many more.

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What Is Powder Coating?

Powder coating is a polyester-based coating method that uses consistently sized, dry polyester microbeads. The beads have an electrostatic charge that enables them to adhere to base materials. Powder coating creates a stronger, more durable and more resilient finish than paint and is useful on products that will need to stand up to harsh weather conditions or provide years of quality use.

Applying powder coating works via a different process from the one used to apply paint and other coatings. Most coatings go on as liquids because their liquid forms are more adhesive than their dry forms. Liquid paint, for instance, goes on as an evaporating solvent.

In the powder coating process, manufacturers typically apply dry powder electrostatically with a spray gun and then cure it in a curing oven or beneath ultraviolet light, giving it exceptional durability and resistance. The curing process also allows manufacturers to apply powder coating to various materials beyond traditional metals, including carbon fiber, composites, fiberboard and plastics.

Most powder coating materials take one of two forms:

• Thermoplastics: Thermoplastics, such as nylon and polyvinyl chloride (PVC), can go through heating, molding and curing more than once. They are easy to alter post-curing, and their coats are easy to remove. They are also ductile and chemically resistant.
• Thermosets: Thermosets, including epoxy resins and phenolic resins, can go through curing only once. Once cured, though, they have greater heat resistance and are more suitable for high-temperature applications.

Powder Coating Advantages

These are a few of the benefits of using powder coating on metal surfaces:

• Hardness and durability: The curing process makes powder coatings tough and durable. The finished coating will not peel or flake.
• Corrosion resistance: The powder coating creates a barrier to protect against many different types of corrosion, including rust. Many natural metals like steel rust over time with exposure to moisture and oxygen. Powder-coating creates a protective barrier so the metal remains rust-free. Untreated aluminum does not rust, but it can oxidize to form a chalky-white substance in place of rust. Most metal parts designed for outdoor use have powder coatings to protect them from the elements and the resulting deterioration.
• Visual appeal: Powder coating also imparts an aesthetically appealing finish to metal surfaces. It is useful on metal products designed for attractiveness, such as patio furniture or visible building components, because it gives them an elegant look.
• Cost-effectiveness: Another advantage of powder coating is its cost-effectiveness compared with other strengthening methods. Manufacturers can create strong products with specific, durable alloys, but those alloys tend to be costly. For instance, stainless steel is renowned for its strength and corrosion resistance but is expensive to produce and obtain. Using carbon steel and coating it with protective powder is a much more economical solution.
• Environmental responsibility: Powder coating is also relatively environmentally friendly. It contains almost no volatile organic compounds (VOCs) and no heavy metals like chrome.

Powder-Coated Steel

Powder-coated steel combines the naturally robust character of steel with the longevity and corrosion resistance of powder coating. Its strength, durability and resistance to many types of corrosion make it suitable for use in outdoor furniture, indoor furniture frames, metal canopy frames, metallic roofs, windows and doors, scaffolding, cranes and trailers. Many outdoor products designed for strength use powder-coated steel.

Is powder-coated steel rustproof? It is, up to a point. Powder-coated steel is highly resistant to rust in most cases, so it won&#;t develop unsightly rust patches or leave red streaks on a patio or building facade. However, if it sustains damage, small cracks in the coating may appear, admit moisture and allow rust to form. If you&#;re looking for a strong, rustproof material, however, powder-coated steel is the closest you are likely to find.

Here are a few of the benefits of using powder-coated steel:

• Strength: Powder-coated steel is tremendously strong. It provides security and peace of mind in architectural applications and makes for dependable furniture as well.
• Longevity: Powder-coated steel is highly durable. Its efficient coating makes a tight seal to keep out contaminants and enable the steel to last longer.
• Thick, consistent finish: An paint application may clump in some areas and remain thin in others. Powder-coating provides a thick, even finish for more consistent protection.
• Aesthetic appeal: Untreated steel may look rugged and unrefined, but powder-coated steel can be beautiful. Finishes in numerous styles and colors mean powder-coated steel products enhance the decor of any building.
• Corrosion resistance: Like other powder-coated metals, powder-coated steel is highly corrosion-resistant. Its coating acts as an impenetrable barrier to keep moisture and other contaminants out, so corrosion cannot gain a foothold in the metal.

Powder-Coated Aluminum

Powder-coated aluminum blends the lightweight properties of aluminum with the resistance and longevity of powder coating. It is easy to transport, and it stands up well to harsh weather conditions without corroding. It is highly suitable for products such as metal patio furniture, metal railings, doorknobs, door frames and window frames.

These are a few of the benefits of using powder-coated aluminum:

• Lightness: Powder-coated aluminum is light and easy to move. It makes furniture rearrangements and product shipments efficient and effortless.
• Durability: Despite its lightness, powder-coated aluminum is tough. It can withstand rigorous outdoor use and last for years.
• Elegance: Though it is strong and dependable, powder-coated aluminum is also aesthetically pleasing. The variety of possible colors and stylish shapes makes powder-coated aluminum products appealing as furniture or decor.
• Corrosion resistance: Like other powder-coated metals, powder-coated aluminum is advantageous because of its corrosion resistance. It shuts out moisture and other contaminants to keep products corrosion-free.

Contact Finishing Systems for Quality Powder-Coating Equipment

To see the benefits of working with corrosion-resistant material in your operations, partner with Finishing Systems for finishing equipment. Our powder-coating booths enable you to provide resistant, reliable powder coatings to boost your products&#; quality and longevity.

You can choose from several options to suit your unique finishing needs. We offer completely integrated turnkey systems, compact batch booths for small spaces, automated conveyor systems for high-volume coating projects and various parts and accessories to help your equipment maintain its optimal performance.

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