Paint & Coatings Industry - April 2009 - (Page 44) Factory-Applied UVImpact on Building Products Industry ost architectural coatings are applied on the job site, but that may change when it comes to building components produced from composites, vinyl and cement fiber. During the next few years, many manufacturers that produce decking, fencing, trim and siding from these materials are expected to introduce products with enhanced field performance achieved by factory-coating their products with new UV-curable coatings. These patent-applied-for coatings, available in a wide range of colors, offer superior resistance to sun, moisture, heat build up and use damage. They can be applied using vacuum, spray roll or other common application techniques. The coating is then subjected to intense UV light and cured almost immediately. The coating can be applied as part of an in-line or off-line process and can be formulated to be soft and flexible or hard and scratch resistant. It can be a clear coat or pigmented in virtually any color or gloss level. From the manufacturer’s perspective, this system has the advantage of utilizing a coating that is 100% solids, so it contains no VOCs or HAPs and is not flammable. M Composites Once virtually every deck in the country was constructed of wood. Currently there are an estimated 30 million installed wood decks. But after a few years of exposure to the sun, rain and humidity, along with being spilled on and scratched during use, wood decks become a bit of an eyesore and need to be refinished – an oft-dreaded task whether deck owners do this themselves or pay to have it done. Fences, rails, door and window trim also require eventual maintenance. First introduced in the 1990s, composites were promoted as eliminating or vastly reducing the need for maintenance. Sales of composite fence, decking and railing products are expected to reach $11.8 billion by 2012. Composite window and door components are also available, but it was learned that over time, composites also tend to exhibit poor fade, scratch, stain, abrasion and mold/mildew resistance. They may also retain heat during hot weather, an unappealing feature for a deck. As a result, regular maintenance is also required. Composites are produced by blending a variety of raw materials. The mixture is then extruded into profiles with many shapes, sizes and lengths including dimension lumber type boards. Composites can generally be sawed, nailed, screwed and otherwise worked like lumber. Their inherent strength makes them ideal for decking and fencing applications. In order to give composites a wood-like appearance, pigments have been added during the mixing stage and wood patterns are embossed on the surface. By Ken Burton, President | Finishes Unlimited, Sugar Grove, IL 44 APR IL 2009 | W W W . P C I M A G . C O M Wood plastic composites, which currently dominate this category, are produced by creating a blend of thermoplastic, wood flour and other chemicals. As time passes, manufacturers are using additional raw materials to replace wood such as fly ash, carpet fibers and agricultural fibers such as hemp and rice hulls as they strive to reduce their reliance on wood and create a “greener” product. The application of UV-curable coatings appears to be the solution to the field performance problems exhibited by all of these composite substrates. Tests show that they provide long-term resistance to fading. UV-coated composite decks also resist scratching from pets walking or children playing on them as well as stains when food or beverages are spilled. The moisture-fighting feature of the coating prevents mold and mildew growth. From a sustainability perspective, this process uses very little energy and has virtually zero waste. Within a manufacturing facility, it requires a very small footprint relative to other coating operations and can be easily adapted to any process making linear substrates. Also significant is the fact that the broad color options for these coatings gives architects and designers the ability to utilize color as a primary decorative feature for a deck, a fence or house trim. In future years the composite can be repainted a new color if the home or building owner desires. These UV-curable products are a coatings industry breakthrough. Historically, composites have resisted coatings because the surface of the substrate prevented adequate adhesion. The formulation of the patent-pending UV coatings allows them to bond tightly to the surface. With composite manufacturers constantly experimenting with new raw materials, there may be differences in the ability of these products to accept coatings. In these instances, there are a variety of processes to treat the surface so it will accept the UV-curable coatings such as fluoro-oxidation, plasma, corona or flame. Fiber Cement Siding The demand for siding products may increase as homeowners opt to remodel their homes prior to trying to sell them during a soft housing market. Of all remodeling options, new siding is reported to generate the greatest return on a remodeling investment when those homes sell. Fiber cement siding has been a construction industry staple since the early 1900s and can benefit from an increase in siding industry sales due to its long life span and reasonable installation costs, which are much less than natural stone, cedar or wood. And, manufacturers http://WWW.PCIMAG.COM
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