What is Pre-painted Galvanized Iron and How to Use It?
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Galvanised Iron (GI) is a metal alloy; either steel or iron, that has a layer of protective zinc coating applied to the surface to prevent rust. Prized for its protective steel properties in its zinc coated form, GI makes the perfect finished steel product for the industrial and construction industry. The most commonly used processing method, which we use here at Camasteel, is through hot-dip galvanizing.
Galvanized Iron (GI)Galvanized Iron (GI)
Pre-painted galvanized iron (PPGI) is another form of GI, formed in a similar process. The process is extended where it refers to factory pre-painted alternative to the zinc coated steel. The hot dip metallic coating process, where the iron is submerged in molten zinc is typically used to coat steel sheet and coil which may all be factory pre-painted like PPGI.
What is Galvanized Iron (GI) and Pre-Painted Galvanized Iron (PPGI)?
PPGI is color coated GI steel, sold in coils or sheet forms, including profile sheets and plain sheets. It is one of many steel products offered here at Camasteel. This pre-painted steel has characteristics of high durability, and resistance against adverse weather and UV rays from sunlight. PPGI is also light weight, with usage cutting across various industries, such as transportation, advertising and construction.
Pre painted galvanised iron (PPGI) coil manufacturer from coated steel coil manufacturers. PPGI coil for construction.
PPGI coil is a rolled-up form of the color steel sheets. Besides, it is a great investment project, because it can be further processed for different uses. Prepainted galvanized steel coil often weighs from 3 to 5 tons. Although, at Camasteel weight is customisable according to your needs.
Prepainted Galvanized Iron (PPGI) coilPrepainted Galvanized Iron (PPGI) coil
A PPGI sheet is the sheet form of the pre-painted steel coil. It is a derivative product of color galvanized coils after shearing, profiling, etc. It is a kind of semi-finished or finished product, which can be for suppliers or end-user direct use. We can find PPGI plain sheets and profile sheets, both of which allow for customisation of the length, width, designs, etc.
(PPGI) Galvanized Color Coated Sheet- PPGI roofing sheet(PPGI) Galvanized Color Coated Sheet- PPGI roofing sheet
There are many different forms of a PPGI steel coil, such as galvanized pipes, steel wires, car parts and frames. Due to the diverse options, GI color coated sheets is utilized in many commercial and industrial instances:
PPGI can be used in buildings, and have varied applications; the exceptional strength and dimensional accuracy of Pre-painted Galvanized Iron coils optimizes the finished product result for, ceiling accessories, lighting, interior cladding and much more:
PPGI can be used for both internal and exterior parts for automobiles and more. As a highly valued Chinese steel manufacturer, with a wealth of connections to steel suppliers who operate globally, we can benefit from the durability and corrosion resistance of PPGI, which maximizes ROI for transport.
PPGI can be utilized to manufacture home appliances, such as the side door plate of freezers and refrigerators, DVD player set shells, LED TV’s air conditioners, microwave ovens and washing machines. Their durability means the steel products being sold offer increased value to the end user!
PPGI can be used in the solar energy industry, typically, to manufacture storage tanks of solar water heaters, alowith with related parts. Technological advancements led to the development of self-cleaning PPGI steel products featuring increased hydrophilic properties and anti-contamination abilities.
Camasteel applies the properties to our PPGI products to ensure contaminants such as dust can be washed away by rain when connecting with the surface of these products.
PPGI can be used to build furniture, this is because it has high-quality three-dimensional designs, is cost effective, high precision steel designs, nano-environmental technology, and more.
It is particularly attractive for being a steel alternative to replicate wooden and marble designs effectively! Pre-painted Galvanized Iron is also very effective as a thermal insulation wallboard and can particularly maximize interior design efforts! Other uses of PPGI (prepainted galvanized steel coil) for the furniture industry are:
PPGI can be used to build electrical cabinets, which in turn are used to store and preserve electrical or electronic equipment.
The material structure of the pre-painted galvanized steel coil is composed of galvanized sheets as a metal base, with zinc coating serving as a layer. The overall thickness of Camasteel PPGI is 0.12mm to 2.0mm:
The base metal in PPGI is usually cold-rolled steel, Camasteel uses a hot-rolled technique which gives the galvanized iron its strength and durability.
A hot dip metallic coating process is applied to coat the steel sheet and coil. In this hot dip galvanizing method, the base metal is submerged into molten zinc to add the protective coating.
Chemical pretreatment, otherwise known as chemical conversion treatment is where the chromate coating is added for extra protection.
In prepainted galvanized iron, the product is painted before the hot dip metallic coating process.
Whilst the back paint thickness is roughly 5-20μm, the top paint thickness is 10-25μm. This helps to ensure the longevity of the product's beauty and use.
PPGI sheet metal componentsPPGI sheet metal components
The paint coating material used on galvanized iron is polyester (PE) and the color of the back paint is white gray. The color can be customized according to our Camasteel color chart, directly adapted from the RAL color deck. Camasteel also offers customisations here; special patterns can be made, e.g. wood grain, camouflage, brick. Check out RALs color chart - tap the image to see the full range of RAL colours! At Camasteel we can personalise your PPGI to these colours and much more:
RAL Color Coating options for PPGI and other Steel Products
Choosing the correct pre-painted steel coil can be achieved by first assessing your natural environment, along with use environments, and structural characteristics of the building to match the appropriate steel grade are among the most important things to consider when choosing an appropriate pre-painted steel coil to match with the required specifications.
This is determined by properties of the chosen material (yield strength, elongation and malleability), performance of metallic coating, considering the metallic coating type, girth, and adherence, and coating performance; coating species, color, sheen, endurance, workability, etc.
The main consideration for the selection of color-coated steel sheets is geographical due to weather implications and how corrosive the environment may be.
Due to the beauty and durability being a key selling point for the use of PPGI on civil buildings, it is imperative that the coating resists discoloration and pulverization.
To understand the pricing of PPGI, you must first understand the characteristics and what to look for. The specifications of the prepainted galvanized iron will be an indicator of the price.
The thinner the base steel thickness, the higher the price of the ppgi steel coil, because the processing cost becomes higher. As a wholesaler, we will offer discounts for bulk-buy orders, book a call to hear our latest offer and promotions!
You can calculate the weight of your PPGI sheet steel, with just four pieces of data:
Length (m) * width (m) * thickness (mm) * density = (kg/pcs)is the ultimate formula for accurate measurement!
To ease the process, we have listed the densities of metals commonly bought in coil and sheet form:
Material Density (g/cm³) Steels 7.85 Stainless steel 7.9 Aluminum 2.7 Iron 7.87 Zinc-titanium 7.2 Copper 8.93Density variations in painted, alloy, or coated steels are minute and can be disregarded. It is imperative that any end results arrived at via self-calculation or utilizing steel calculator tools online, should be considered estimations, rather than exact calculations.
The approximate coil weight can be determined by measuring the Density (D), Thickness (T), along with the Outside (OD), and Inside Diameter (ID).
Measuring the weight of PPGI coil (diagram)Measuring the weight of PPGI coil (diagram)
The first would have to be the Intact zinc coating on GI by Camasteel that prevents corrosive substances from breaching the surface of the underlying steel or iron. This longevity and resilience make PPGI the perfect building material!
The differences between PPGI and PPGL can be analyzed with regards to substrates, durability, weight, appearance, features, applications and price:
PPGI uses a galvanized steel substrate as base metal. These galvanized sheets have a layer of zinc coating. However, PPGL uses galvalume cold-rolled steel sheets as a substrate. Galvalume sheets for PPGL are coated in 55% aluminum, 43.3% zinc, and 1.6% silicon.
PPGL sheets have a higher resistance against PPGI sheets, due to the dense layer of aluminum, which prevents the base metal from eroding.
The surface of a PPGL sheet is smoother than PPGI sheets. This is because aluminum is more adhesive than zinc.
PPGL is 3x more durable than PPGI; AI-ZN coating in PPGL is more resistant to corrosion, in comparison to the ZN-rich in PPGI.
Due to the lesser weight of aluminum when compared to Zinc, PPGLs AI-ZN coating is lighter than PPGIs zinc coating. Although, AI-ZN coating can occupy 3% more space than the GI sheet, even with the same weight.
PPGI and PPGL can be used for industrial and commercial purposes, including; automobiles, wall paneling, roofing etc. However PPGL is more suitable for adverse outdoor environments, due to its high corrosion resistant features.
PPGI sheets are 3%-11% lower in cost than PPGL sheets, due to varied, but minute reasons of process and material variance, durability and feature differences.
PPGI steel coil proves more aesthetically pleasing due to the color and smooth appearance. It is light in weight, making it cheaper and easier to transport, especially in bulk! PPGL on the other hand is more expensive but the product lasts longer.
PPGL can also withstand up to 315 ℃ temperatures, due to the higher density aluminum coating. Book a quick consultation/take a look at our pricing breakdown page to see how we can customize the selection and distribution process for you!
PPGI is a well-rounded and multifunctional steel product. Ultimately design life and environment, along with the specifications should help you make your final choice.
We also offer a consultancy service for those who need extra information and assistance when buying from us. Email us to speak with one of our specialists as soon as today!
All in all, there are many uses for pre-painted galvanized iron and there are many intricacies involved in its procurement. Consultancy from an efficient PPGI manufacturer like Camasteel can help to minimize confusion in your buying journey. Don’t forget to leave any further questions in the comments below.
Part 1 PPGI Introduction
Explain PPGI coatings
PPGI stands for “Pre-Galvanized Iron” or “Pre-Galvanized Steel”, PPGI coating refers to the application of a layer of paint or other protective coatings to galvanized steel sheets or coil before it is used in various applications such as corrugated roofing sheets, or building materials. PPGI coatings offer many essential functions and benefits in different applications. This coating process offers a variety of advantages, including enhanced corrosion resistance, improved aesthetics, and protection of the underlying metal substrate. The coating process typically involves cleaning and pretreating the galvanized steel surface to ensure proper adhesion. The selected coating material is then applied using methods such as roller coating, coil coating, or spraying. Coated steels are cured or baked to ensure that the coating adheres firmly and provides the desired properties.
The impact of coating selection
Selection of the appropriate PPGI coating can have far-reaching ramifications on all aspects of a project, from performance and longevity to aesthetics and environmental considerations. Here are several key areas where coating selection has a substantial effect:
1. Corrosion Protection:
Positive Effect: Securing metal components with corrosion-resistant coating can extend their lifespan while decreasing maintenance costs and replacement needs over time. Choosing an effective protective layer can thus extend their useful lives by years if not decades!
Negative Impact: Selecting subpar or incompatible coatings can result in premature corrosion and rust formation, jeopardizing the structural integrity and safety of assets.
2. UV Resistance:
Positive Benefit: UV-resistant coatings offer many advantages over their UV counterparts by shielding materials from damaging rays, and helping reduce fading, degradation, and maintenance needs.
Negative Impact: Poor UV protection can result in color fading, surface degradation, and decreased aesthetic appearance.
3. Durability and Longevity:
Longer UV exposure is associated with increased PPGI coating surface degradation as well as an overall decrease in aesthetic appearance.
Positive Impact: High-quality coatings can significantly extend the lifespan of building materials, decreasing repair or replacement needs and costs.
Negative Impact: Poor coating choices could accelerate material degradation sooner than expected and necessitate costly repairs or replacements sooner than planned.
4. Energy Efficiency:
Cool roofing coatings and reflective coatings can decrease cooling costs for buildings by limiting heat absorption, contributing to greater energy efficiency.
Negative Impacts: Non-reflective coatings could lead to higher energy consumption and utility bills.
5. Aesthetics and Appearance:
These coatings may affect aesthetics and appearance as well as performance.
Positive Impact: Coatings that provide a wide range of color options and durable finishes can enhance the visual appeal of structures while adding curb appeal.
Negative Impact: Poorly chosen coatings may result in color fading, chalking, or an unattractive aesthetic which diminishes the overall appeal of a building.
6. Environmental Impact:
Positive: Eco-friendly coatings that contain lower levels of volatile organic compounds (VOCs) and are recyclable can support sustainable construction practices.
Negative Impact: Coatings that contain high volumes of volatile organic compounds (VOC) or harmful substances could have detrimental impacts on the environment and may not meet sustainability goals.
7. Maintenance Requirements:
To be sustainable, regular maintenance requirements should be observed.
Positive Impact: By selecting suitable coatings, properly selected coatings can significantly decrease maintenance frequency and costs, saving time and resources.
Negative Impacts: Inadequate coatings may require frequent upkeep resulting in increased maintenance expenses as well as potential disruptions of operations.
8. Compliance With Regulations:
Positive Impact: By selecting coatings that comply with local building codes and regulations, projects will meet legal and safety requirements.
Negative Impact: Non-compliant coatings can lead to project delays, legal complications, and additional costs to bring it into compliance.
9. Cost Considerations:
Positive Aspect: The selection of coating can have an enormous effect on overall project costs by impacting maintenance expenses, energy efficiency levels, and future replacement needs.
Part 2 Understanding PPGI Coatings
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Application of PPGI
Electrical appliances:
Refrigerators, display cases of frozen foods, washing machines, electric ovens, pan recorders, amplifiers, auto booths, air-conditioners, electronic computers, duplicating machines, switch cabinets, instrument cabinets, electric fans, dust collectors, etc.
Transportation industry:
Car ceilings, backboards, boarding interior decorating plates, vehicle shells, trunk plates, passenger cars, instrument plates, shells of control consoles, trolleys, tramcars, train ceilings, partitions, inner walls, doors, inner devices of vehicles, color partitions of steamship, ship furniture and floors, containers, etc.
Sheet metal processing and furniture:
Ventilation heating stoves, petroleum furnaces, shells of water boilers, shells of electric water heaters, counters, racking, signboards, binding lighting lamps, wardrobes, sofas, chairs, lockers, file cabinets, books shelves, etc.
Other aspects:
Shells of musical instruments, electronic organs, weight counts, dustbins, gauges, instrument plates, shells of vacuum flasks, photographic equipment, typewriters, bulletin boards, watches, lighters, packing containers, etc.
Features of PPGI
Corrosion Resistance:
PPGI provides excellent corrosion resistance to the underlying steel. It helps protect the steel from rust and degradation caused by environmental factors like moisture, humidity, and chemicals.
Durability:
PPGI is highly durable and can withstand various environmental conditions, including UV radiation, temperature fluctuations, and mechanical wear.
Aesthetic Appeal:
PPGI comes in a wide range of colors, finishes, and textures, allowing for customization and enhancing the visual appeal of products and structures.
Uniform Coating Thickness:
PPGI is applied using controlled processes, resulting in a uniform and consistent thickness across the entire surface of the material.
Smooth Finish:
PPGI typically produces a smooth and even finish, which is ideal for applications where aesthetics are important, such as building facades, automotive body panels, and appliances.
Ease of Maintenance:
PPGI surfaces are relatively easy to clean and maintain. They resist staining and are less likely to accumulate dirt and grime, making them suitable for applications that require periodic cleaning.
Flexibility:
PPGI is flexible and can be formed into various shapes and profiles without cracking or peeling. Suitable for applications that involve bending or shaping the coated material.
Adhesion:
PPGI adheres well to the galvanized steel substrate, ensuring a strong bond that is resistant to delamination or separation over time.
Chemical Resistance:
PPGI can provide resistance to certain chemicals and substances, making them suitable for applications where exposure to chemicals is a concern, such as in industrial environments.
Weather Resistance:
PPGI is designed to withstand exposure to harsh weather conditions, including rain, snow, and UV radiation. They maintain their color and protective properties even under prolonged exposure to the elements.
Fast Application:
PPGI can be applied efficiently through automated and controlled processes, reducing production time and costs.
Environmental Considerations:
Some PPGI coatings are formulated to be environmentally friendly, with low levels of volatile organic compounds (VOCs) and hazardous materials, meeting regulatory and sustainability requirements.
Customization:
PPGI can be customized to meet specific requirements, including color matching, gloss levels, and performance characteristics, depending on the intended application.
How PPGI coatings are applied and cured?
PPGI (Pre-Painted Galvanized Iron) coatings are applied and cured through a multi-step process that involves surface preparation, coating application, and curing to ensure the coating adheres properly and provides the desired protective and aesthetic properties. Here’s a step-by-step explanation of how PPGI coatings are applied and cured:
1. Surface Preparation:
Cleaning: The steel substrate (typically galvanized or Galvalume steel) undergoes a thorough cleaning process to remove dirt, oil, grease, and other contaminants. This step is crucial for ensuring proper adhesion of the coating.
Degreasing: After cleaning, the steel may be degreased to eliminate any remaining oils or residues. Degreasing enhances the surface’s cleanliness and promotes good adhesion.
Chemical Treatment (Optional): In some cases, a chemical treatment may be applied to the substrate to further enhance adhesion and corrosion resistance. This treatment can include the application of a phosphate or chromate coating.
2. Primer Application:
Primer Layer: The first coating layer applied to the cleaned and treated steel is the primer. The primer serves several purposes, including improving adhesion, enhancing corrosion resistance, and providing a smooth surface for the topcoat.
Spraying or Roll Application: Primers are typically applied using spraying equipment or rollers to ensure an even and consistent layer across the substrate.
3. Topcoat Application:
Topcoat Layer: The topcoat layer is where the color and specific performance properties, such as UV resistance, are incorporated into the PPGI coating. The choice of topcoat material depends on the desired color, durability, and other functional requirements.
Spraying or Roll Application: The topcoat is applied similarly to the primer, using spraying equipment or rollers. Proper application techniques are crucial to achieve an even, smooth, and aesthetically pleasing finish.
4. Curing Process:
Drying: After the primer and topcoat layers are applied, the coated steel passes through an oven or curing chamber. During this phase, the coating is dried, removing solvents and ensuring that it adheres firmly to the substrate.
Curing: Curing involves exposing the coated material to elevated temperatures for a specific duration. This step allows the coating to chemically cross-link and harden, achieving its final properties. The curing process may use convection ovens, infrared heaters, or other heating methods.
5. Quality Control:
Throughout the coating and curing process, quality control measures are in place to inspect and verify the coating’s thickness, adhesion, color consistency, and other performance attributes. Any defects or issues are identified and addressed during this phase.
6. Cooling and Inspection:
After curing, the coated steel may undergo a cooling process to bring it to a manageable temperature. It is then inspected for quality and compliance with specifications.
7. Coil or Sheet Formation:
The coated steel can be further processed into coils or sheets, depending on the specific application and customer requirements.
Coating inspection
Visual Inspection: It involves examining the coated surface for any visible defects, such as pinholes, blisters, cracks, or unevenness, overall appearance, color, and texture of the coating.
Coating Thickness Measurement: The thickness of the coating is an essential parameter to verify its compliance with the specified requirements.
Adhesion Testing: Adhesion testing assesses the bond strength between the coating and the substrate.
Surface Preparation Evaluation: Involves verifying that the substrate has been properly cleaned, degreased, and prepared according to the specified standards， presence of contaminants, roughness, or residual coatings.
Holiday or Pinhole Detection: Holiday or pinhole detection is crucial to identify any small voids or discontinuities in the coating that may lead to corrosion or coating failure.
Destructive Testing: In some cases, destructive testing may be necessary to evaluate the coating’s performance and integrity.
Documentation and Reporting: This includes recording measurements, observations, photographs, and any non-conformities or defects identified during the inspection process.
Part 3 Types of PPGI Coatings
1. Polyester(PE) has good adhesion, a wide range of formability and outdoor durability, and moderate chemical resistance. The service life is 7-10 years.
2. Polyvinylidene fluoride (PVDF) has good formability and color retention, excellent outdoor durability and powdering, solvent resistance, and limited color. The service life is 20-25 years.
3. Silicon-modified polyester(SMP), which has good hardness, wear resistance, and heat resistance, good external durability and non-powder ability, and limited gloss retention and flexibility. The service life is 10-15 years.
4. High-weathering polyester(HDP) has excellent UV resistance and high durability, and its main properties are polyester and fluorocarbon. The service life is 10-12 years.
Part 4 Coating Selection Factors to Considerer
PPGI Coating Corrosion resistance
Corrosion resistance is an integral factor of Pre-Painted Galvanized Iron (PPGI) coatings, as it determines their ability to withstand corrosion, rusting, and degradation when exposed to various environmental conditions. PPGI coatings are specifically tailored to enhance galvanized steel’s corrosion resistance – making them the perfect choice for applications where protection from rusting and degradation is a necessity.
Galvanized Substrate: PPGI starts with a galvanized steel substrate. Galvanization involves applying a layer of zinc onto steel surfaces to act as a protective anode against rust and corrosion in its wake.
Primer Layer: PPGI coatings typically incorporate a primer layer, applied directly onto the galvanized substrate. This layer serves various purposes, including improving corrosion resistance by providing an additional protective barrier between the zinc layer and the environment preventing direct exposure of steel to moisture and oxygen.
Topcoat Layer of PPGI Coatings: The topcoat layer provides additional corrosion protection by being composed of corrosion-resistant pigments, resins, and additives designed to enhance their ability to withstand environmental factors.
PPGI coatings typically incorporate additives that enhance corrosion resistance, such as inhibitors to decrease corrosion rates and barrier pigments to block moisture and oxygen from reaching underlying steel surfaces.
PPGI Coating UV resistance and color durability
UV rays can lead to degradation and fading of colors over time, diminishing their aesthetic appeal and compromising the protective properties of coatings. To combat this effect, PPGI coatings are specifically formulated with excellent UV resistance properties; ensuring their colors remain vibrant while still offering sufficient protection from prolonged sunlight exposure. In order to enhance UV resistance further, special additives and pigments that absorb or reflect UV radiation may be included within their formulation to increase protection; additionally, high-grade resins and binders contribute to greater UV resistance.
Color durability is another essential characteristic of PPGI coatings, and undergo extensive tests to assess their color stability, such as exposure to UV radiation, temperature variations, humidity changes, and abrasion resistance.
Important to keep in mind that while PPGI coatings are designed with UV resistance and color durability in mind, prolonged exposure to harsh environmental conditions may still result in some degree of color change or fade over time. By selecting high-quality PPGI coatings with proper maintenance practices in place and providing regular cleaning and inspection services, their UV resistance and color durability can be maximized for lasting performance and aesthetic appeal.
PPGI Coating Chemical resistance
PPGI (Pre-Painted Galvanized Iron) coatings are widely acclaimed for their outstanding chemical resistance – an invaluable quality when exposed to various chemicals or corrosive substances. Chemical resistance of PPGI coatings can be achieved by selecting resins and additives with inherent chemical resistance, depending on their intended use in an application such as one where acids may be present; such applications might use acid-resistant resins that can withstand their corrosion-causing effects. In addition to their resin system, PPGI coatings may include special additives that increase chemical resistance. Proper surface preparation and application techniques are also critical to optimizing the chemical resistance of PPGI coatings. Thorough cleaning of substrates prior to pretreatments like phosphating or chromating helps promote adhesion while increasing resistance against chemical attack. Furthermore, regular inspection and maintenance checks should be conducted on coated surfaces to detect signs of chemical damage or degradation.
PPGI Coating Ease of maintenance
Use of PPGI coatings that exhibit excellent corrosion resistance can significantly decrease maintenance and refinishing costs, and cause less disruption among building owners and occupants. This results in cost savings as well as less disruption.
Part 5 Conclusion PPGI Coating
In short, the correct selection of PPGI coating is very important in the right project. They affect the appearance, longevity, and overall performance of the roofing material. Color, thickness, length, and width can be customized according to your requirements.
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