The Problem
Metal cladding is used all over the world to cover warehouses, factories, facades and many other types of buildings. They are subjected to extreme conditions and stresses due to their constant exposure to ultraviolet radiation, pollution and aggressive weather.
Sheets expand and contract continuously under the influence of changing temperatures, At the same time they need to protect against corrosion and degradation from continuous exposure to the elements. In Heavy Industrial C4 and C5-M Coastal environments corrosion is more aggressive due to the salt and industrial pollutants in the atmosphere.
Colour and gloss will fade or becomes chalky, rust quickly sets in especially on cut edges and around bolts and welds. Spot corrosion may also occur around mechanically damaged areas leading to rapid pitting and loss of metal.
As the rust creeps the original coating will begin to peel and delaminate leaving the metal exposed to accelerated corrosion. Steel or aluminium sheets will corrode dramatically once breached, with significant loss of coating and ultimately metal. Galvanized steel sheets will begin to show white zinc chloride corrosion salts as the first sign of degradation, followed by metal loss.
Elastometal is an easy to apply and a cost-effective solution. An anticorrosion waterproof elastomeric coating which will considerably extend the life of your building in C4 Heavy Industrial and C5-M Coastal environments.
It forms a rubber like waterproof membrane on the metal, with excellent adhesion and anticorrosion properties.
For a hard to touch architectural finish it can be overcoated with a topcoat of Metal Unicoat available in a range of RAL Classic and NCS colours in a matt 15% finish.
The Solution
Elastometal
Elastometal is a high performance ecological and sustainable coating with excellent corrosion resistance, adhesion and flexibility. With 200% elasticity it has the flexibility to withstand expansion and contraction of metal cladding panels without cracking or detachment.
Applied direct to metal, it is a single product solution for renovating metal cladding panels in an aggressive Industrial C4 and C5-M Coastal environments.
It can be applied direct to steel and weathered galvanized sheets subjected to corrosion. A Low Odour, Low Emission, Ecological and Sustainable coating available in an extensive range of RAL Classic and NCS colours. Available in 5kg and 25kg containers for free delivery throughout the UK.
Elastometal has a rubber like touch and appearance, it provides a waterproof anticorrosion coating with excellent adhesion. For a hard to touch architectural finish it can be overcoated with a topcoat of Metal Unicoat available in a range of RAL Classic and NCS colours in a matt 15% finish.
Metal Unicoat, a High Performance Ecological and Sustainable fast drying topcoat, which provides a smooth durable weather resistant finish with excellent colour and gloss retention.
Recommended quantity and thickness
The recommended dry film thickness for Elastometal in coastal and industrial environments is 175 microns (7 mils) with a total coverage rate of 0.4kg per square metre.
The recommended dry film thickness for Metal Unicoat is 95 microns (4 mils) with a theoretical coverage of 5 square metres per litre.The total recommended dry film thickness required is 270 microns.
Benefits & Performance
The Elastometal-Metal Unicoat system has a global track record Waterproofing, Protecting and Decorating metal roofs and cladding. It delivers great benefits to the owner of the building in terms of a cost-effective maintenance solution for metal cladding in harsh environments. Applied direct to weathered metal cladding without the need for abrasive blast cleaning. It has excellent adhesion to weathered galvanised sheets, plastisol and pvdf coated cladding panels. For the applicator it is a simple safe, easy to apply two coat system without the need for abrasive blast cleaning.
For the project manager:
- Economical solution. No abrasive blast cleaning required.
- Ideal in Heavy Industrial & Coastal areas.
- High performance and exterior durable system.
- Ecological and Sustainable paint.
- Low VOCs and Emissions. No fire risks.
- Low Odour, minimal disruption.
- Made in the West Midlands.
- Wide choice of RAL & NCS colours.
- Free Delivery no hidden costs.
For the applicator:
- No abrasive blast cleaning required.
- Suitable for weathered galvanised sheet.
- Quick drying and overcoating.
- Easy and safe to apply.
- No isocyanates or pot life issues.
- Low Odour, Low Emissions. No fire risks.
- Proven track record.
- Made in the West Midlands.
- Wide choice of colours.
- Free Delivery to site.
Preparation
Weather
As with any outdoor project, try to avoid starting a job in wet conditions. A minimum of 10 °c (50 °f) and no rain forecast during and immediately after application are required to be able to apply the product successfully. Above 15 °c (59 °f), working conditions are perfect and enable higher productivity. If the project is located in a very hot area with very intense sunshine avoid applying the system when the sun is the most intense and work early in the morning or in the late afternoon.
If you are working in humid climates, and especially if it is cold after sunset such as in the autumn, be sure to complete the job a few hours before dark. Avoiding the risk of condensation covering the fresh paint and slowing drying. If you are working at dawn, be mindful of condensation on the surface.
Surface preparation
The surface must be clean, dry, degreased, and free of any contaminants.
Eco Powerclean a powerful biodegradable alkaline concentrate composed of anti flash rust additives should be used for cleaning and preparing surfaces before painting. When high pressure water blasting up to 4% Eco Powerclean can be added to clean water to improve degreasing and temporarily protect the surface from flash rusting. After application the surface should be left for 2 to 3 minutes for it to react with the metal. It will significantly improve the corrosion protection on exposed metal surfaces and reduce cleaning times. At 5% dilution usage is 100m2 per litre. Allow to dry before applying Metal Unicoat.
High pressure water blasting is recommended at a minimum of 180 bar / 2600 psi equipped with a rotating zero-degree angle nozzle. This method will remove surface contaminants, loosely adhering paint and rust.
Cleaning by mechanical or power tools is advised when more detailed surface preparation needs to be done on objects within the roof, such as chimneys, access ladders and bolts that could be heavily rusted.
Moss and mould can be removed with Eco Powerclean biodegradable solution.
Inspect and threat bolts
It is important to inspect the condition of the bolts securing the metal panels to each other and to the roof structure. Defective fasteners and bolts must be repaired or replaced.
Brush on a coat of Elastometal on each fastener after inspection. This will help visualize the progress of the inspection and add a protective first layer on vulnerable areas.
Edges
Check the edges of roof and cladding sheets. These are places easily subject to corrosion. Remove all contaminants and apply a stripe coat of Elastometal by brush for additional protection.
Preparing the products
Products are supplied ready for use. Mechanically stir the products for a few minutes before the application.
If you are working in hot weather conditions, you may dilute the coatings with tap water to slow its drying. But do not add more than 3% of water in order not to reduce its anti-corrosion properties.
Elastometal and Metal Unicoat are ideally applied by brush on localised areas such as ladders and piping, airless spray should be used for large areas. If spraying is not possible, you can apply by roller although more coats will be required to achieve the recommended dry film thickness.
Equipment
Elastometal when applied by airless spray use a pressure of at least 180 bar or 2600 psi and a spray tip between 0.017 and 0.023 inches.
Metal Unicoat when applied by airless spray use a pressure of at least 180 bar or 2600 psi and a spray tip between 0.013 and 0.019 inches.
For application by roller, it is recommended to use 14 mm / ½ inch polyamide rollers.
Both products can also be applied using the Graco Ultra Max portable airless device. It's a simple and effective method for small jobs or for touch-ups on larger scale projects.
System Application
The application
If you intend to use a dry film thickness measuring device, measure the thickness of the remaining coating or galvanized steel to later calculate the total applied thickness. If you do not have this device, you can use a wet film gauge during the application.
Application by airless spray is recommended as fewer coats will be required. Apply the first coat of Elastometal to a dry film thickness of 175 microns. Allow 4-6 hours between coats.
Apply the second full coat of Metal Unicoat over the entire surface to a dry film thickness of 95 microns. Finally, finish details such as metal objects, corners and edges with a paintbrush to make sure they are well covered.
The total dry film thickness of the applied system should be 270 microns. After 4 hours of drying at 20°c, the coating is dry and resistant to rain.
