Coil & Cut Sheet Handling and Protection

Mr Paresh Shah, DGM, JSW Steel

Introduction
Configuration of Prepainted material

(Layer 1) Top coat in various colours (Layer 2) Suitable Primer (Layer 3) - Pretreatments. (Layer 4) Zinc or Al-Zn coating (Layer 5) - steel sheet

(Layer 6) Back coat

Topics covered

Handling of Material In Plant Transportation Handling and Preservation at Warehouse Handling and Preservation at Job site Care to be taken during Forming and installation Dos and Don'ts

Handling of Material at Plant

Handling of Material

Care taken at plants:

Packet lifted with Woolen felt only to avoid damage to edges.

Handling of Material

Care taken at plants: Coil handled with C-Hook padded with Woolen felt.

The floor should be flat & clean.

Handling of Material

Care taken at plants: In the plant, Padding on hooks and other handling devices helps to avoid damage on edges. Cushioning materials like feltboard and polyurethane protect coils while they are moved, placed in inventory or shipped.

Handling of Material
Care taken at plants:
Material stored in dry and good ventilated shed

Handling of Material
Care taken at plants:
Coil kept on Rubber pads to avoid dent on outer wraps

Handling of Material

Always keep the material in a dry, shaded and good ventilated area.

Do not keep the material under direct sunlight and open area.
Do not keep the material on wet floor (water, rain, etc.). If not required for immediate use, provide cover to protect the material If Sheets become wet during storage, it should be separated without delay & surface moisture removed with clean cloth. The steel sheets then be stacked so that air circulation completes the drying process.

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Handling of Material

Good Storage conditions can eliminate the followings: Moisture penetrating between the Sheets. Moisture or water penetrates between the Sheets through the wooden pallets. Wet storage staining. White rust. Paint peel off.

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What is White rust & How it is caused?

White rust is a complex, hydrated zinc carbonate/zinc hydroxide. It is a corrosion product of zinc which is formed under specific conditions of exposer. The most common causes of white rust are : Ingress of water, due to rain water between the adjacent surfaces in a stack of galvanized or pre painted steel or sheets or within windings in a coil during either transportation or storage. Condensation within a coil or sheets due to rapid changes in temperature, Condensation from the drying out of new buildings or laying & drying out of wet concrete. Prolonged , adverse storage or inadequate protection during transportation allowing considerable water ingress between stacked coils or sheets results into some time red rust also .

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Transportation

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Transportation
Transport driver should check material must be covered with double tarpaulin. Other goods should not be transported with pre painted material. Ensure no water seepage during transportation. Ensure there should be no hole on the floor of truck to avoid water seepage. Truck platform should be flat

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Transportation
GI coils and Packets: Coils and packet have to be kept on the wooden Block on Floor Proper Lashing to be done Never allow a coil to contact the floor directly.

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Transportation
BGL, PPGI and PPGL Coils : These products have to be Kept on the truck with vertical packing (Eye to sky) to avoid transit rubbing marks on the surface. Truck needs to be covered with tarpaulin to avoid any water seepage during transportation.

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Warehouse

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Storage of coated steel product at Warehouse

Following care needs to be taken for the coated steel product to avoid any damage to the coating Avoid the water seepage inside the packed coils and packets. Material is to be kept on the Dry surface to avoid moisture contact.

Packed coil and packets are to be store and stacked properly in a closed shade to protect the material from the rain water.

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Stacking of material
Coils should remain packaged to prevent rust till further processing Partially processed coils should be repacked for future use Coils should not be allowed to butt-up against safety rails or walls or floor plates Metal-on-metal contact should be avoided whenever possible. Coil/sheet stock should be stored in dry conditions. The floor should be free of debris. Minimize coil stacking, but when required Band clips should not reside between touching coils Felt strip padding should be placed between coils Narrower coils should be stacked on wider coils

Highter weight coils should be stack on heavier coils

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Stacking of material
Coils should be stacked with sufficient distance in between for SAFE material handling Coils should not be stored in open yard

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Recommendations : Ensure the material condition is OK during unloading of the material.

If any deviation is observed, same should be recorded in L.R. copy.

Ensure there should be no damage to the goods during unloading (woollen felt, Rubber coated C-Hook etc. can be used)

Do not slide sheet on rough surface or over each other.

For personal safety and to protect the surface finish, wear Clean, Dry Hand Gloves.

Rotated on a first-in/first-out basis

Organized to minimize unnecessary coil/sheet movement Arranged so coils can be easily reached in the order you plan to use

them

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Stack Corrosion
Water is a necessary perquisite for corrosion of stored pre painted panels Water or water vapor may penetrate between panels or coil wraps due to capillary action Ambient humidity and temperature cycles will also promote water intrusion into stored panel bundles through condensation. Besides water, two other important factors that contribute to the corrosion of stored pre painted panels are temperature and exposure time. Corrosion will accelerate with increased temperature. Given enough time, panel bundles will eventually become wet and storage corrosion may occur under most job site panels. Storage/ stack corrosion can be prevented by: Reducing site storage time.

Decreasing water contact.

Moderating temperature extremes
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To be avoided

Material Kept on soil - no flooring

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To be avoided

Material Kept in open condition

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To be avoided

Improper Material handling causes fold mark / scratches on the sheets

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To be avoided

Inadequate warehouse building

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Handling of Material at Job Site

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Handling of material at Job Site

Material should be stored in covered condition

Material to be kept slightly above the ground by using wooden rubber plank.
Do not slide sheet on rough surface or over each other. Contact with water / mud should be strictly avoided For personal safety and to protect the surface finish, wear Clean, Dry Hand Gloves. After Erection / Assembling, Guard film should be removed immediately.

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Handling of material at Job Site

When lifting bundles with a forklift, forks must be a sufficiently apart to avoid buckling of the sheets. Do not transport open bundles. Forklift arms should be padded If Coil is handled with Hydra, nylon slings should be used with sufficient padding on the edges.

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Handling of material at Job Site

Panels in bundles should be lifted at their center of gravity. When lifting bundles with a crane, a spreader bar and nylon straps should be used. Never use wire rope slings. Individual panels should be lifted vertically by the seam. If the panel is over 10 feet long, lift it with two or more people on one side to prevent buckling Do not pick up the Panel by the ends.

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Actual on-site photos

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AVOID Storage of material in mud water

Material should not be stored in open and wet condition

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AVOID - Stacking of material in mud

Material should be protected from water During storage as well as during forming at site
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AVOID Dirt accumulation on the sheets

Material should be stored in covered and dry condition

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AVOID water entrapment in the packet

Water entered in the packet

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AVOID leaving Debris on the sheet

Iron fines from drilling, saw cut chips & fasteners lying can cause rust stains. Leaving debris on the sheets may lead to such type defects. Sweep swarf from roof after finishing installation
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Proper Fastener Installation procedures to be followed

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AVOID - Contact with Cement

For Bare and Prepainted Galvalume products, direct contact with cement foundations is not recommended. Accelerated corrosion can occur due to the lime contained in the cement.
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AVOID Metal Filings

Metal debris from sawing, drilling and other construction processes should be removed during installation. Otherwise, the metal filings will red rust on the surfaces where they were deposited. Red rust of the metal filings may cause stain or discoloration on the surface of the panel whether it is bare or painted and cause appearance issues.
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AVOID Dirt Accumulation on the sheet

Two types of dirt accumulate on buildings: dry soil and greasy or organic residues. The dry dirt, by itself, washes off with rain or high-pressure water spray. Greasy residues do not wash off in rain and hold dry soil and chalk tightly to the surface.
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Guard Film / Lamination

Water can enter through Guard film, which may lead to paint peel off as shown above. Guard Films are provided only for forming operations and to avoid handling scratches

This water entrapment is because of the capillary actions of the Gap Between sheets which get entrapped in the packet while stacking / storage. As the permeability of paint coating increases in intact conditions, this failure / phenomenon will result. This is highly restricted for the pre painted products hence not a process defect. Guard film should be removed immediately after installation
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Forming Operation

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Roll Forming Operations

For Roll Forming of pre painted material, Rolls should be properly polished. There should not be any damage on the rolls. Maintain the roll forming equipment to achieve proper vertical and horizontal tooling alignment, as well as adequate clearance between the mating top and bottom spindle rolls to avoid abrading the coating. Clean the rolls to avoid damage to the paint finish. Incorporate the appropriate number of roll forming stages to ensure smooth transitioning of bends.

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Roll Forming Operations

Use suitable paint system to maximize performance at bends. Design the roll former to accommodate the strength of the steel grade. For example, a higher strength steel may require more roll former stands to successfully produce a given profile. Use lower strength steels to allow greater design latitude when making more complex profiles. eg. - Tile Profile

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Roll Forming Operations

Rolls should be properly polished to avoid damage to paint

Roll Damage

Roll damage may lead to paint peel off during roll forming Paint peel off
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Summary
Pre painted material consists of various layers of paint system. This paint system, if used properly can give maximum life span and best appearance possible. This is not a metal bonding and susceptible to physical damage if not handled properly at various stages of operation.

Before installation
store in dry keep covered

ship in covered condition

handle as per the guide line onsite protection

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Colour Coating Line Product Range

Strip thickness Substrate Strip width Coil ID Coil OD Weight Coating material

: 0.20 - 1.50 mm : Galvanized & Galvalume Steel : 600 - 1250 mm : 610/508 mm : 1500 mm max. : 3 - 10 T : Polyester, Si-Polyester, Polyurethane, PVDF, Epoxy Primer Coating Thickness : Top = 5 max : Bottom = 5 max Top & Back Coat thickness: Top = 25 max : Bottom = 5 max Guard Film : Optional

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THANK YOU

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