Customer Info_Naturall_Decoral_170207

General Information for Aluminum Surfaces in Wood and Stone
Optic based on the System-Finish Methods Naturall® und
Decoral®
Status 02/2007
As part of Schüco System-Finish services, profiles as well as sheets can be finished with
wood and stone optics by using the coating processes Naturall® and Decoral® .
This information explains these processes, their differences and common properties as well
as the required checks for feasibility and to explain the limits of these methods, which should
be known if ordered and must be accepted by the customer.
1. Finish processes creating wood and stone optics
These processes are two-steps methods, which are more demanding and complex than the
standard one layer powder coating process. Independently of the applied process, the base
coat is a powder layer in the base color of the chosen optic (e.g. a light brown for a wood
finish or a white for a stone optic similar to marmor). The applied powder is of a special type
normally in facade quality, which differ strongly in delivery time and price from the normal
stanard RAL colors. This base coating in powder is performed on the complete accessible
surface, both the main and the side viewing areas are uniformly covered.
Within the Naturall® process (sample surface compare Picture 1), a second thinly applied
and differently colored powder is applied via a matrix, which contains the desired structure
(wood texture stripes or stone surface impression) formed by very fine holes within the matrix.
The second powder, generally in a darker color than the base color (compare Picture 2) falls
through the holes of the matrix onto the Aluminum surface already covered with the base
color. Both layers are being held onto the Aluminum by electrostatic forces. To fixate the
created impression, both layers are then burned into the Aluminum by heating to object
temperature (ca. 170 to 190°C). Due to the distance between matrix and Aluminum as well as
due to the geometry of the part to be covered (planar, convex, concave, three-dimensional), a
technically unavoidable distortion of the intended wood or stone impression may occur.
Depending of the area size of the main (profile viewing area) and side viewing area (profile
functional area) it is technically unavoidable that small size areas are covered only by parts of
the structure and very small size areas are covered only by the base color and contain no
texture at all. These optical differences are due to technical restrictions of the process and
define no reason for a claim. Depending on the layer thickness of the second coating, the
texture can be feeled, which increases the character of this coating in relation to natural
products such as stone or wood. Both powder layers are certified by independent quality
groups for use in building applications.
Pictures 1 and 2: Surface Finish Naturall® Ever Green in real size and by factor 20
enlarged
Base Color
Color of Texture
For the Decoral® method, the transfer of a pigment from a a carrier (paper or foil) into the preharded but poros base coating is used (sample surface compare Picture 3). For this process,
the part to be covered (profile or sheet) must be in contact over all areas with the carrier
which contains the pigment. The transfer of the pigment into the powder coating to create the
texture is performed by using heat and vacuum. The texture created with the Decoral®
process cannot be feeled in contrast to the above described surface created by the Naturall®
process (compare Picture 4). Only the powder layer of the Decoral® process is certified by
an independent quality group.
Pictures 3 and 4: Surface Finish Decoral® Eiche Golden Oak in real size and
by factor 20 enlarged
Base Color (light)
Color of Texture
(diffused into Base
Color)
2. Informationen regarding Optical Limits
Masters for available wood and stone textures are created from real nature samples, which
are copied and transferred either onto a matrix (Naturall®) or onto a paper or a foil based
carrier (Decoral®). Due to the size limits of those masters and limits in the transfer process,
the resulting Aluminum surfaces also show the natural differences of those masters (intensity,
unique features of the wood, texture distortions) as well as their repititation (compare
Pictures 5 – 7).
Picture 5:
Decoral® Surface Golden Oak Sheet Sample 1 in size A5 (Explanation Sample
Optic)
Picture 6:
Decoral® Surface Golden Oak Sheet Sample 2 in size A5 (Explanation Sample
Optic)
Picture 7:
Decoral® Surface Golden Oak Sheet Sample 3 in size A5 (Explanation Sample
Optic)
This results technically into different optics based on the uniform surface of the profiles if
viewed in running direction as well as over this width of these profiles (compare Pictures 8 to
10). When different profiles build together, e.g. as part of a window or a door, this results in
the contact of different aspects of the same texture as common in products from nature.
These different aspects of one texture as well as the missing of the texture on very small
functional areas of a profile (only base coat visible) is no reason for a claim but due to the
chosen geometry of the Aluminum profile.
Picture 8: Decoral® Surface Golden Oak Sample Texture 1 from Picture 5 (Illustration of the
effect of local texture optics & viewing width)
Picture 9: Decoral® Surface Golden Oak Sample Texture 2 from Picture 5 (Illustration of the
effect of local texture optics & viewing width)
Picture 10: Decoral® Surface Golden Oak Sample Texture 3 from Picture 5 (Illustration of the
effect of local texture optics & viewing width)
Due to the existence of texture directions in both processes (within the matrix as well as on
the carrier) the customer has to include in his order a drawing showing the build-up of the
profiles. Without this required information the finish is always applied in running direction of
the profile. Optical differences (different texture directions) on the finish build-up of those
coated profiles due to missing information of the build-up situation from the customer cannot
result in a claim to Schüco.
3. Overview of possible Textures
The finish of Aluminum parts with a texture creating Surface such as Naturall® or Decoral®
should be based on a detailed explanation of the processes as well as by a check of the
usability of the chosen profiles and sheets for these processes.
The selection of a surfaces finish in either Naturall® or Decoral® must be based on the
current issue of the Schüco color booklet. Please consider that the given illustrations in the
Schüco color booklet are based on photo reproductions of planar sheets. Differences of those
textures on three-dimensionally formed Aluminum parts (profiles or formed sheets) as well as
differences due to the repititation of the master are no reason for a claim. After pre-selection
of possible surface textures, Schüco will order a sheet sample of the chosen wood or stone
texture in standard size (GSB test plate size or max. A5). Profile samples or larger sheet
samples are possible only as orders against payment and within the agreed delivery time due
to the complex production process and the wide range of possible textures. Parallel to the
sampling process with Schüco, the customer should sent a complete overview of the profile
geometries (Schüco ordering numbers) as well as for the sheet geometries (drawings
including sizes) to Schüco in order to check the feasibility. A guarantee for the feasibility can
be given by Schüco only after completion of this check together with the coating partner. The
positive confirmation of the feasibility and the confirmation of the customer order does not
imply that Schüco or the coating partner guarantee the optical uniformity of the provided
sample on the chosen Aluminum parts of the customer. The technical limits outlined within
part 2 are still valid and must be considered.
4. Special Textures
Besides the potential textures for Naturall® und Decoral® outlined in the current issue of the
Schüco color booklet, other textures or the production in different powder qualities (high
durable quality, with pre-anodizing to prevent filiform corrosion) may be possible. Normally,
both processes are performed with powder in façade quality. To check if this quality is
useable, the customer must inform about the local conditions (climate, emissions, intended
usage). Production in an alternative, non-standard optic, in a different powder and/or pigment
quality or the finish of complex formed sheet structures may result in changes for both the
prices and the delivery time. This ís due to additional processes as well as for the ordering of
special raw materials normally not in stock. In case of complex formed sheets, special tooling
costs to set-up the equipment for handling those customer parts may be required which are
also to be paid by the customer. After receiving the above outlined customer information
Schüco will inform the customer about feasibility, price and expected delivery time.
5. Feasibility Check for Wood and Stone Textures
Enclosed to this information, the QM information sheet for Naturall® and Decoral® provides
additional important information for consideration by the customer:
A mixing of materials finished by both processes even if the chosen surface finish will have
the same name is not possible due to not acceptible texture differences arising from different
masters, methods of repitiation and process parameters.
The provided illustration of surface finishes and the resulting finishes on Aluminum
parts may show technically unavoidable color and texture differences. The given
pictures are intended only for illustration and are not guaranteed as results.
The applicability of these processes upon pre-selected profile and sheet geometries are
different and require, as stated under point 3., a check and confirmation of feasibility by
Schüco and the coating partner.
6. Schüco QM Information Sheet May 2005