Formulations of Powder Coatings
Describe the different types of powder coatings?

Powder Manufacturing
How are powder coatings manufactured?

Application of Powder Coatings
Can powder coatings be applied directly to metal substrates?
Under what conditions can powder coatings be applied?
How long do powder coatings last when kept in the carton?
How do I maintain a powder coated finish?

Features & Benefits
 What is the typical life expectancy of a powder coated finish?
Can powder coatings withstand any condition and be applied to oxidized substrates?

Safety, Health, & Environment
 How safe are powder coatings?

Specifications & Standards
 What are some of the common performance reference standards used for evaluating powder coatings?
Is there a certification program or verification program for powder coatings applicators?

Fluoro Guard™ Technical Data

Formulations of Powder Coatings
Describe the different types of powder coatings?
There are a variety of powder coatings available in the commercial market today. Each type has different properties for a particular use. Epoxy and Hybrid powder coatings are generally used for interior industrial and commercial applications, since these resins have poor UV resistance. Urethane and TGIC Polyester powder coatings can be used in both interior and exterior exposure applications. Fluoropolymer containing powder coatings offer superior weathering performance and corrosion resistance in marine and architectural environments.
Powder Manufacturing
How are powder coatings manufactured?
A powder coating is produced by dry-blending resins, pigments, additives, and curing agents together, and then extruded at elevated temperatures to produce a melt-mix of the formulated ingredients. The extrudate is immediately cooled and pressed into a solid sheet, where the formulated coating material is progressively kibbled and ground to a well-defined particle distribution for spraying by an applicator.

Application of Powder Coatings
Can powder coatings be applied directly to metal substrates?
While powder coatings normally require no primers, it is important to provide a clean and properly pretreated surface for the powder coating to adhere. For steel substrates, it is advisable to abrasively blast clean prior to coating and applying an iron or zinc phosphate pretreatment. For aluminum substrates, it is advisable to provide a chromate or chrome-free conversion coating to the aluminum surface. Chrome-free pretreatments are rapidly replacing hazardous chromate pretreatments.

Under what conditions can powder coatings be applied?
Powder coatings are generally a one-coat finish, applied to a properly cleaned and pretreated substrate. Prior to spraying, the powder coating material is generally sieved and then fluidized for 10 minutes to condition it. Powder coatings are a factory applied finish using specialized equipment. The equipment consists of electrostatic spray guns (manual or automatic), a powder spray booth, and an oven to bake (or cure) the coating. On-site application is not possible given the hot curing cycle required to fuse the coating to the substrate.

How long do powder coatings last when kept in the carton?
The powder coating's storage life varies according to the resin technology and the storage conditions at the applicator. If the powder coating is stored under improper environmental conditions, the materials will absorb moisture and become lumpy. Follow the powder manufacturer's recommendations for storage conditions and always re-test stored powder to confirm no degradation in film properties.

How do I maintain a powder coated finish?
In order to realize the maximum life from a powder coated finish, correct periodic cleaning procedures need to be followed. Generally, a mild soap or detergent ruled safe for bare hands should be safe for cleaning of the coating surface. Further information on cleaning and maintenance of organic coatings may be found in the AAMA publication 609 & 610-02.

Features & Benefits
What is the typical life expectancy of a powder coated finish?
This is a frequently asked question. The adhesion and film integrity of the powder coating is dependent on the proper pretreatment of the substrate and curing of the applied material.
Most standard exterior grades of powder coatings are designed for general use and offer good weathering resistance, excellent film integrity, and very good hardness. Fluoropolymer containing powder coatings offer superior resistance to sunlight and UV degradation, saltwater attack, corrosion, and are less permeable to moisture.

Can powder coatings withstand any condition and be applied to oxidized substrates?
Unfortunately, there is a myth that since powder coatings are so much easier to apply than liquid coatings, and offers a very hard film, they can withstand anything. This carefree approach has lead to some disappointing applications and negativity in selecting powder coatings for premier architectural projects. Powder coatings rely on a clean and properly pretreated substrate. Oxidation deposits, which are corroded material, must be removed prior to applying the powder coating. Not all powder coating resin systems meet the same performance standards. A complete examination of the type of powder coating must be thoroughly reviewed prior to its selection for a particular use. The applicators qualifications, operational equipment, and quality control procedures play a significant role in the life expectancy of the powder coated finish.

Safety, Health, & Environment
How safe are powder coatings?
Powder coatings contain no solvents, which simplifies their transportation and storage, but are classified as a nuisance dust. Workers should use proper dust masks, protective garments, gloves and skin creams to prevent inhalation or contact with their skin. Use mild soap and water to remove from skin contact. Since powder coatings contain no solvents, they do not release hazardous VOC's (volatile organic compounds) or HAP's (hazardous air pollutants) into the workplace or the environment.

Specifications & Standards
What are some of the common performance reference standards used for evaluating powder coatings?
There are a variety of standards established to measure the coatings performance. The most common tests include gloss and color measurement, adhesion, hardness, abrasion, chemical resistance, and weathering performance. These tests are covered under the International Organization for Standardization and/or The American Society for Testing and Materials.

Weathering performance tests are conducted using a number of methods to assure the powder coated finish will maintain its gloss and color. Due to the competitive nature of the construction materials market, many companies cannot wait 10 or 15 years for actual field test results to bring a product online. Accelerated testing allows companies to rapidly evaluate their coating technology against a known standard for accessing gloss and color retention, chalking and fading resistance, chemical resistance, salt spray humidity, and adhesion. Every major manufacturer in the construction materials market utilizes accelerated testing in conjunction with field testing to constantly verify the life expectancy and performance of their products.

Is there a certification program or verification program for powder coatings applicators?
Certification or verification programs are usually valid for 12 to 24 months, and require certifying after this period to verify that the applicator can correctly apply the coating. For example, AAMA (American Architectural Manufacturers Association) specifies physical properties tests and the evaluation of such tests to verify that application lines have correctly applied the coating. Specific coatings are not included as a part of their verified components program.
Many powder coating manufacturers test or verify their coatings through the American Association for Laboratory Accreditation (AALA Certified) under non-disclosure agreements.