Powder Coated Timber in the Construction Industry

Powder Coated Timber in the Construction Industry

How Gas Catalytic IR technology from Heraeus has enabled a unique breakthrough in the construction industry

 

Powder Coated Timber

It is often said that brilliant ideas are 1% inspiration and 99% perspiration. Jeff Stewart, co-founder of Climate Coating Ltd, found his 1% whilst watching a large wooden wall being painted single handed by a weary decorator. If it were a steel section wall, Jeff would have powder coated it, so why not try powder coating timber to see if it worked? Then the 99% perspiration kicked in and Jeff joined up with Kyle True from the timber industry, and the rest, together with ground breaking technology from Heraeus (formerly Vulcan Catalytic Systems) is history. One of the primary problems with powder coating a timber substrate is its heat sensitivity. The time required to cure powder in a conventional hot air oven (20 – 30 minutes) would cause significant damage to the timber. The creative solution was to use Gas Catalytic IR. The IR waves are easily absorbed by the powder which will now cure (7 – 10 minutes), without overheating the substrate. The result is a patented process that is having a big impact in the construction industry.

As the world population continues to increase, the need for sustainable, low waste, energy efficient commercial and residential buildings has become a necessity. The founders of Climate Coating Ltd. in New Zealand have pioneered and patented innovative methods of creating powder coated surfaces on plywood, MDF and plasterboard. The majority of these products can be fitted without any further finishing requirements and are available pre-cut to size and in many colours. They include:

  • Pre coated plasterboard for walls and ceilings
  • Decorative MDF board for commercial fit-out
  • Moisture resistant exterior grade plywood
  • Pre primed exterior finishes that do not need to be finished for up to 3 months

So how do Climate Coating Ltd.’s products contribute to the drive for sustainability? The answer is multi layered and is evidenced not just by the product itself and its place in the market, but also by the innovative, energy efficient method of manufacture.

Product Advantages

The advantages of pre-finished products themselves are self-evident. By creating pre-finished and pre-sized materials that are commonly found in every type of construction, the reduced need for wet trades (brick laying, plastering and painting) has a significant impact on building lead time. Delays due to weather, material supply and waste are all but eliminated. Consider the number of half used tins of paint and wasted bags of plaster that are commonly seen on building sites! The products are also ideal for the pre-fabricated building industry.

Manufacturing Advantages

Dig down deeper, and further very significant advantages can be discovered. As Climate Coating Ltd pre-finish the board materials in a purpose built factory, the efficiencies of having a precisely controlled process means that waste is virtually eliminated and a consistent level of quality control is achieved which far surpasses that which can be accomplished “on site”.

One of the vital elements of the production system is the use of Gas Catalytic IR ovens to efficiently cure the applied powder on the chosen substrate. The system, designed in conjunction with world leaders Heraeus (formerly Vulcan Catalytic Systems) has proven to be a wise choice. The systems produced by Heraeus have proven to be the most controllable, energy efficient powder coat curing solutions available today.

The powder curing system details are as follows:

  • Two coat system
  • 2 PLC controlled Gas Catalytic ovens (2 section preheat and 5 section main cure)
  • 300m2 per hour output
  • Space saving design has small footprint
  • Programmable to control the heat output horizontally and vertically through the oven
  • Perfect cure obtained by using only the exact amount of required Infra-Red.

What Climate Coating Ltd say about Heraeus:

“Having the world leading industrial IR process heating guys on board from the outset was an inspired choice on our part. Their in-depth knowledge and experience was key in enabling the Climate Coating Ltd concept to become a reality”

Kyle True (MD Climate Coating Ltd [climatesurfaces.com])

Key Product Points

  • Sustainable, no VOC’s produced in manufacture
  • Extremely high level of quality control that is unachievable “on site”
  • On site wet trades eliminated
  • Ideal for pre-fabricated buildings

Key Gas Catalytic IR powder curing points

  • Measurable and consistent process
  • Highly controllable (PLC) and adaptable
  • High quality finish
  • Energy efficient process
  • Small footprint

Gas Catalytic Heaters Provide Quicker and Better Finish on Boats

catalytic heatersKey improvements by switching to Catalytic Heaters

  •   Quicker job completion
  •   Improved gloss finish
  •   Flexible system
  •   Safe to use in hazardous environment
  •   30 % operating cost saving

 

The International Marine Composites company in Bristol, Rhode Island, USA is at the centre of the vibrant East Coast yachting industry. The ability to complete a wide range of boat repairs, and paint refinishing is key to the company’s success. Generally, the marine industry relies upon wet finishing systems which usually comprise a wet epoxy primer underneath a two part polyurethane finish which gives the desired hull colour. Further protection to the high gloss finish can be provided by an extra two part polyurethane clear coat.

Multipurpose boat sheds tend to be big, cold and dusty which makes high gloss finishing difficult to achieve. The cold atmosphere can cause an “orange peel” effect on the finished paint, so the generally accepted method of heating the shed is to use a hot air circulation system, prior to wet spraying. Unfortunately the air movement causes dust to become airborne which can then land on the newly painted surface. Curing of each coat can take up to 24 hours, which means that a simple paint job can take 3 – 4 days.
Jorge Borges, owner of International Marine Composites approached Heraeus Vulcan (formerly Vulcan Catalytic Systems) for help in speeding up the complete process, and improving the finish on completed boats. Our engineers quickly determined that 30 minutes of Gas Catalytic IR Heat could be used to pre heat the boat hull prior to the wet spraying of the epoxy primer. This was then followed by a further 20 minutes of IR heat. Heaters were arranged on a movable and easily adjustable framework, which can be positioned up to 2.5m away from the boat hull. By using this method there was no unnecessary air movement and a tack free and dust free primer could be achieved and cured very quickly. Previously, the epoxy primer coat required 24 hours of cure time before it could be rubbed down. With Gas Catalytic heaters, this can take place after just 6 hours. The same process can be repeated when applying the polyurethane paint and clear coat.
The end result is a boat hull which finish which meets proud owners expectations of a high gloss finish with no imperfections. The added advantage is that Jorge can complete a simple paint job in a day.

Vulcan Catalytic Systems © 2012–Present  |  All Rights Reserved  |  Admin
Website Network Setup Toni Mills Graphic Design | Content & SEO - Chris Chapman