CATALOGO_PINTURA_EN

ADVANCED SOLUTIONSIN PAINT COATINGS

Experts in urban equipment +34 93 852 1000

BENITO’s long history and experience in painting has enabled it to develop

its own way of working, oriented towards quality and customer service

while meeting environmental demands at all times. The fact that we are

manufacturers obliges us to take care over every single detail from beginning

to end of the process.

Sensitivity to colour and texture together with professional rigour and

efficiency have made us a benchmark in the field of industrial painting and

a driver of innovation within the surface treatment sector. Anticorrosion

treatments are among the primary concerns of our quality department.

For this reason we have more than 6,500 square metres of facilities equipped

with the latest coating technology (both for industrialised processes using

powder paints and for more traditional ones using liquid paint). BENITO

has various paint lines and a flexible, environment-friendly industrial structure

designed 100% to optimise processes and resources.

A comprehensive, efficient structure which allows us to take on the widest

possible range of orders, including those from industrial sectors which

demand special preparations, high micronage, high-strength pieces or very

delicate items.

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Introduction

Advanced solutions in paint coatings

DESIGN

QUALITY

INNOVATION

MANUFACTURING


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ENTS

Close to the two paint lines the company currently runs, BENITO has

installed two fully computerised storage towers to facilitate access

to and monitoring of paint stocks, as well as making it possible to store

materials under ideal temperature and humidity conditions.

The proximity of these smart paint storage towers to the test laboratory

also facilitates technical analysis of the paint before beginning the

production process.

Smart paint store on the BENITO site.

A latest-generation pain line

BENITO recently started up a latest-generation paint line at its new

production plant. This line is specially designed for large, heavy pieces

and allows powder coating of pieces up to 7 metres long and weighing

1,000kg.

This facility is the only one of its kind in Spain, with a length of 980

metres and taking up 2,000 square metres of floor space.

BENITO has a new powder coating line for large and heavy pieces.

Facilities

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High capacityThe line allows pieces up to 7m long weighing 1,000kg to be

coated.

Flexibility: twin-rail conveyor (Power & Free)The twin-rail conveyor allows each frame to be set up for a

different, specific cycle.

The fully automated process is controlled by the programme

according to the information linked electronically to each frame.

In this way the best use can always be made of the resources

available and the booth distribution.

When the work programme calls for it, the electronic conveyor

management system takes the frame to the waiting area and

then into the pre-treatment tunnel or application area.

Versatility: two paint application boothsThe incorporation of two booths (designed by Wagner) makes

it possible to work with different colours and rhythms. A total

of 4 oscillators and 28 automatic spray guns are fitted, plus 4

manual guns, all with corona charge.

The frames for pieces are distributed according to a coded

programme, by means of rail switching, to booth 1 (used for

the main colour) or booth 2 (characterised by shorter colour

change times).

Better resultsAt the exit from the application area, the conveyor line enters

the infra-red gelling tunnel and the surface temperature of the

pieces rises rapidly, gelling the powder applied.

This process avoids subsequent loss of paint, prevents

contamination between frames coming from the two

application booths and guarantees a better end result.

Better working conditionsFrom a productivity point of view, the three loading units (and

two unloading units) enable operators to work under the best

possible conditions regardless of the size of the pieces, which

are always loaded with the frame stationary.

The fitting of lifting systems also makes the job of loading and

unloading easier in the case of heavy pieces.

New powder coating line

The Power & Free twin-rail conveyor is able to handle the frames independently. It is built to work with very heavy loads.

The cycle begins in the pre-treatment tunnel with a thorough degreasing and ends with final drying.

Inside the IR tunnel, where the powder is gelled.

This phase prevents contamination between the frames coming from the two application booths.

Entrance to the polymerisation oven. Next to the IR tunnel are the structures of the final absolute filters, connected to the air/dust separation cyclones on the overspray recovery circuit.

New powder coating line

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After the pre-treatment phase, the pieces pass through a large booth for the application, if required, of liquid products (wash primer or other base preparation products).

The installation works with absolute filters to prevent any emissions of paint to the outside.

The lifting systems ensure proper care of the pieces during handling and make the operators’ job easier.


Technical monitoringBENITO has two test laboratories equipped with all the

measuring apparatus necessary to verify proper finishing of

the pieces during the process or at the end. This guarantees

that the pieces will work perfectly and last a long time in

the future.

Colour monitoring

Micronage

Shine

Density of the paint

Adherence

Impact resistance

Torsional resistance

Drawing

System for monitoring and verifying pieces

Quality

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Main treatementsDepending on the type of metal and its subsequent use,

BENITO assesses and carries out the most suitable type of

paint treatment:

Advanced pain solutions

BASE TREATMENT (NO SHOT BLASTING)

TREATMENT SEQUENCE

Shot blasting

Degreasing

Rinsing

Phosphating

Passivation (chromic or non-chromic) Rinsing in demineralised water Drying Painting

TYPE OF METAL

Hot rolled steel

HIGHLY ANTI-CORROSIVE TREATMENT

TREATMENT SEQUENCE

Shot blasting and/or degreasing

Rinsing

Passivation (chromic or non-chromic)

Rinsing in demineralised water

Drying

Zinc-rich primer

Painting and polymerisation

TYPE OF METAL

Clean mild steel

Pre-treated steel

Steel with iron phosphate

Treatments

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Base treatment with shot blasting Special highly anti-corrosive treatment

General view of the hook shot blasting machine and detail of the centrifugal turbines.

DescriptionShot-blasting, or cleaning by propelling abrasive material against the surface, is

simply a way of working cold. Compression forces are induced in the exposed

surface layer of the metal objects by the impact of a stream of shot directed at

the surface of the metal at high speed under controlled conditions.

Another advantage, which was its primary function, is that it increases fatigue

strength.

The processThe process has other beneficial uses such as dissipating the tensile force which

contributes to cracking, forming and consolidating metal parts and accepting

adherence for any subsequent treatment of the parts.

There are four grades of rust, the state of the surface before shot-blasting, and

four grades of preparation of the surface depending on the rust grade (s 1, Sa 2,

Sa 1/2 and Sa 3). These grades are regulated by the UNE-EN ISO 8501-1 standard

and supplement, on the basis of which it can be stated that the grade of preparation

carried out is A Sa 3.

The shot used has a martensitic structure and a Rockwell hardness value of

40<HRC<51. The roughness values obtained are (depending on the quality of the

material being shot blasted):

Ra-> from 5 to 9 micra

Rz-> between 20 and 40 micra

1. Base treatment (no shot blasting)


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Effect on the product of the shot blasting process.

Sa 1

Sa 2

Sa 2 1/2

Sa 3

Rust grades on steel surfacesBefore applying anti-corrosion paint to steel surfaces the surface is prepared in a

particular way to ensure a durable finish. The preparation grade will be different

in each specific case, and this is why four rust grades on steel surfaces and four

preparation grades for these surfaces have been established.

1. Steel surface largely covered with a layer of adherent mill scale but little or no

rust visible.

2. Steel surface with the beginnings of rust and from which the layer of mill scale

is starting to flake off.

3. Steel surface where the layer of mill scale has disappeared due to corrosion or

where the layer of mill scale comes off when scraped, but in which no large visible

cavities have formed.

4. Steel surface where the layer of mill scale has disappeared due to corrosion and

where large visible cavities have formed.

Preparation grades

1. Light shot blasting

Loose mill scale, rust, coatings and foreign particles are removed. The appearance

must match the figures for Sa 1.

2. In-depth shot blasting

The whole layer of mill scale, rust and nearly all foreign particles are removed. Any

residual contamination must be firmly adhered. The surface is then cleaned with a

dust exhaust, clean dry compressed air or a clean brush. It must take on a greyish

colour and its appearance must match the figures for Sa 2.

3. Very in-depth shot blasting

Layers of mill scale, rust and foreign particles are removed so completely that the

remains are only visible as light stains or scratches. The surface is then cleaned with

a dust exhaust, clean dry compressed air or a clean brush. Its appearance must match

the figures for Sa 2 1/2.

4. “Bare metal” shot blasting

The layer of mill scale, rust and foreign particles are removed completely. The surface

is then cleaned with a dust exhaust, clean dry compressed air or a clean brush.

Afterwards it must be a uniform metallic colour and match the figures for Sa 3.

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DescriptionThis powder coating process is used when the metal needs special

anti-corrosion protection features.

It can be used on mild steel cleaned by shot blasting and on

pre-treated steel, though in the latter case there is a reduction in

the anti-corrosion protection.

Without cleaning by shot blasting, it can be used on ferric

phosphated steel (for best results, chromate passivation and rinsing

with demineralised water is recommended).

BENITO is the first Ferrus user approved in Spain to use this

advanced anti-corrosion process as a result of which the metal

can withstand more than 1,000 hours in the saline mist chamber

according to the ISO 9227 standard.

The process

1. Shot blasting and/or degreasingThis phase uses shot blasting to remove all kinds of dirt from the

metal: rust, mill scale, oil, grease or burnt grease, especially in the

case of welded pieces, for which a mechanical treatment is

necessary to remove the films of rust (see further details of the

shot blasting process in the section on base treatment).

2. Priming with zinc-rich powder – FerrusIn this phase a primer using epoxy powder with a high active zinc

content is applied to the metal. This combined system offers greater

anti-corrosion protection in aggressive environments and high

durability outdoors.

The primer consists of a system of double-layer powder which is

applied in two stages:

Stage 1

Ferrus primer

Baking at 200ºC MT

Stage 2

Coat of Ferrus polyester finish

Baking at 200ºC MT

3. PaintingAfter the zinc-rich primer the powder paint coating is applied. This

has a double function: appearance and protection.


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2. HIGHLY ANTI-CORROSIVE TREATMENT

Tests conducted with the Ferrus anti-corrosion system

Sprayed with neutral salt (ISO 9227). With and without marking

Result: over 1,000 hours with no loss of adhesion

Natural exposure. Volvo SCAB corrosion test.With marking.

Result: excellent behaviour under 24 months exposure on a marking panel and excellent edge protection

MAIN ADVANTAGES OF TOTAL SOLUTION IN POWDER COMPARED TO LIQUID PRIMERS:

No solvent emissions A more environment-friendly process Faster processing times Eliminates the liquid painting process Makes best use of the facility

Ferrus after shot blasting, Sa 2.5 Ra 6-7 micra SCAB test. 24

months’ forced outdoor exposure.

To achieve the best possible results on each product the most

suitable treatment is sought for the substrate (iron, cast, wood,

plastic, etc.).

Depending on this, BENITO seeks zinc-based epoxy primers

or those with other new bases brought onto the market by

the top names (Akzo Nobel, Dupont and Adapta). These provide

the best guarantee in terms of both pre-treatment and final

coatings or finishes.

Our aim is to provide solutions to problems, with the best liquid

and powder applications, not only to protect against vandalism

but also anti-adhesive, anti-poster and anti-graffiti.

Shot blasting+ D3 polyester

Shot blastingFerrus+ D36 polyester

Shot blastingFerrusD36 polyester

24 months’ reinforced natural exposure

TA about 4km from the sea

Sprayed with saline solution (twice a week)

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Thanks to its rigorous production system, BENITO holds ISO

9001/2000 certification for powder painting of metal parts and

is the first Spanish user of Ferrus high anti-corrosion finishes.

BENITO’s new paint plant is also highly environment-friendly, as

it works with absolute filters which prevent any emissions of

paint to the outside, so caring for the environment.

Guaranteed reliability


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Quality certificates

Design, quality and COLOUR for your city

Exclusive colours for unique site furnishing

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HEADQUARTERS: Vía Ausetania, 11 · 08560 MANLLEU (Barcelona) Spain · Tel. + 34 93 852 1000 · Fax + 34 93 852 1001 · [email protected] · www.BENITO.com

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