Coatings for Extreme Applications - Greenheck

Coatings for Extreme ApplicationsPerma-ZHi-Pro-ZJuly2008

The Page Zinc Header AdvantageIn 1972, Greenheck took the lead as the firstcommercial and industrial fan manufacturer tointroduce electrostatic powder coatings. Today,Greenheck continues to lead by being the first tooffer a superior zinc-rich powder basecoat andpowder coating finish.This zinc-rich basecoat technology is usedextensively outside the HVAC industry to protectbridge beams, automotive components and otherheavy-gauge steel products. Now, this advancedtechnology is exclusively available on Greenheckwelded steel products.Greenheck’s coating process starts with a minimumof five wash stages to treat all components priorto painting. Cleaner parts result in better coatingadhesion and durability. We then use an advancedtwo coat powder application method that includesa basecoat of zinc-rich powder and a topcoat ofGreenheck’s Permatector or Hi-Pro Polyester. Thecombination of these two topcoats over our new zincrichbasecoat results in the two new coatings Perma-Zand Hi-Pro-Z. These oven cured coatings providesuperior corrosion resistance along with a tough,uniform finish to combat the most extreme conditions.To help determine what process and coating maybe right for your specific environment, refer to theperformance tested guide provided on page three.Two Coat SystemWhen compared to a traditional single coatapplication, the benefits of the two coatsystem include:• An automatic powder coat applicationproduces uniform coverage and unmatchedpaint quality.One Coat ProcessTopcoat2-3 milsBase SteelStandardSurface Preparation• The double coat thickness provides superiordurability and protection from air and water.• The zinc-rich basecoat includes an epoxycomponent that provides additional corrosionprotection.• The zinc-rich basecoat provides chemicalprotection of exposed steel to preventcorrosion.Two Coat ProcessTopcoat4-6 mils TotalBase SteelZinc-rich Primer(70% zinc)AdvancedSurface PreparationThe Zinc AdvantageThe zinc-rich basecoat actively andpassively protects the base steel if thecoating becomes damaged and thesteel is exposed to air and water.Damaged SurfaceProtective LayerIf scratched or chipped the zinc donates electronsto the iron, producing immediate corrosion protection.The zinc-rich basecoat has a lowerelectrochemical potential than the basesteel. As a result, the steel is actively held in a neutral state when exposed to a corrosive environment—thedriving force of corrosion is halted. A protective layer forms over the damaged surface as a by-product ofthe chemical reaction and passively protects the exposed steel from further corrosion due to air and water.2

Performance Page HeaderTestedWhen selecting a powder coating finish for heavy-gauge welded steel fans, critical informationsuch as environment, moisture, exposure, abrasives, and chemicals should be considered.Powder coatings are the best choice for most extreme applications. Major advantages overmost vendor-applied liquid coatings include:• Superior finish with uniform coverage and thickness.• A better coating provides better protection.• The process is environmentally friendly.• Unequaled value.One coat ProcessTwo coat ProcessCoatings Color Coating SpecificationsPermatectorStandard coating for steel products inboth indoor and outdoor applicationsHi-Pro PolyesterFormulated for exterior durability,color and gloss retention. Excellent forchemical applicationsPerma-ZTwo coat powder paint coating providesoutstanding corrosion protection inmany extreme applicationsHi-Pro-ZTwo coat powder paint coating isresistant to saltwater, chemical fumesand moisture in corrosive environmentsNote: Perma-Z and Hi-Pro-Z are not available on aluminum.Test DataLight GrayDark GrayLight GrayDark GrayThickness: 2.0 - 3.0 milsPolyester urethanepowder coatingThickness: 2.0 - 3.0 milsHigh performancepolyester urethanepowder coatingThickness: 4.0 - 6.0 milsPermatector topcoatwith zinc-rich, epoxybasecoatThickness: 4.0 - 6.0 milsHi-Pro Polyestertopcoat with zinc-rich,epoxy basecoatClean AirXCoastalEnvironmentsChemical *Extreme WeatherAbrasive ParticlesSun-UVXX X XX X X X XX X X X X X*Chemical-Resistant Rating BelowPermatectorHi-Pro PolyPerma-ZHi-Pro-ZChemical* Chemical Resistance RatingsBleachSulfuricAcid (10%)HCI (10%) MEKChlorine(0.1%)NaOH (20%)Permatector 0 1 2 2 0 —Hi-Pro Poly 0 0 0 1 0 —Perma-Z 0 1 2 2 0 2Hi-Pro-Z 0 0 0 1 0 1RatingdescriptionsSalt Spray ASTM B117Hours 1000 2000 3000 4000PencilHardnessASTM D33630 - No effect 1- Slight change in gloss or color2- Surface etching, severe staining, but film integrity remains3- Significant pitting, cratering, swelling, or erosion with obvious surface deterioration3H2H3H2HDurabilityCross-HatchAdhesionASTM D3359-BNo FailureNo FailureNo FailureNo FailureSalt Spray ASTM B117 is acomparative test that indicatesthe corrosion resistance ofpowder paint coatings.Pencil Hardness and Cross-HatchAdhesion tests determine thedurability of a coating to withstandscratches, nicks and chips.Chemical Resistance Ratingsprovide information on how eachcoating option will hold-up incertain chemical environments.3

Warranty PlusGreenheck’s two coat powder paint system provides unparalleled corrosion protectionin the most extreme conditions. Test data demonstrates our two coat paint systemoffers three and four times the corrosion resistance of other coatings commonlyCoating WarrantyCoating TypePermatector, Hi-ProPerma-ZHi-Pro-ZSpecificationsFrom ShipDate1 Year2 Years2 Yearsavailable within the fan industry. The valueof this unmatched corrosion protection isrealized by our industry-leading coatingwarranty.For detailed warranty and limitationinformation contact your area representative.Multi-Stage WashAll carbon steel components shall be cleaned andchemically treated by multi-stage processes thatshall include alkaline cleaner to remove oil andfilm; oxide removal to eliminate oxide formed onlaser cut components; iron phosphate coating toincrease corrosion protection and paint bond; andseal rinse to seal pores in iron phosphate coatingfor optimum corrosion protection.Available CoatingsPerma-Z shall exceed3,000-hour salt spray underASTM B117 test method. Finishcolor shall be industrial (light) gray.Hi-Pro-Z shall exceed 4,000-hour salt spray underASTM B117 test method. Finish color shall becharcoal (dark) gray.Two Coat Electrostatic Powder SystemFan components shall be coated with a two coatpowder coating consisting of a zinc-rich powderbasecoat electrostatically applied and gelled.Minimum dry film thickness to be 2-3 mils. Thebasecoat Building shall consist Value of 70 percent in Airzinc and shallbe formulated with an epoxy binder.Greenheck delivers value top quality, innovative air-withourelated shall equipment. be We offernotice.A polyester to mechanical urethane engineers powder by topcoatelectrostatically helping them applied solve virtually at a minimum extra value dry film to contractorsthickness any air of quality 2-3 mils challenges atop the basecoat by providing and easy-to-install,bakedsimultaneously their clients with face with the a zinc-rich competitively basecoat. The priced, reliabletotal drycomprehensivefilm thicknessselectionof theoftwoproductscoat powderthat arrive on time.coating system shall be a minimum of 4-6 mils.Our WarrantyGoing GreenSpecify Perma-Z and Hi-Pro-Z for your extremeapplications or for any environment where physicalappearance and corrosion protection is essential.As a result of our commitment to continuous improvement,Greenheck reserves the right to change specificationsAnd building owners andoccupants value the energyefficiency, low maintenanceand quiet dependable operationthey experience long after theconstruction project ends.For decades, Greenheck has focused on theenvironmental side of the building industry—developing reliable, energy-efficient productsand systems to promoteoccupants’ health andcomfort. As one of thefirst manufacturers of airmovement and controlequipment to join the U.S.Green Building Council,Prepared to SupportGreen Building Effortsour desire for sustainablebuildings has extended to ourstate-of-the-art, two coat powder paint system.Our coating system includes pretreatment ofthe multi-stage washer waste prior to release tothe municipal water treatment facilities, a 100%powder paint reclaim system, and infrared curingbooster ovens with energy savings approaching50% when compared to typical convection ovens.Prepared to SupportGreen Building EffortsWe help engineers, architects, contractors, andowners succeed in their green initiatives, on anyproject. Going green? Go Greenheck - visit ourWeb site or contact your area representative.P.O. Box 410 • Schofield, WI 54476-0410 • Phone 4(715) 359-6171 • greenheck.comP.O. Box 410 • Schofield, WI 54476-0410 • Phone (715) 359-6171 • greenheck.comCatalog Rev. # Month YearCopyright © 2007 Greenheck Fan Corp.Coatings for Extreme Applications Rev. 1 July 2008 RGCopyright © 2008 Greenheck Fan Corp.