Episode 41: The Art and Science of Metal Paints with Sherwin Williams

This episode of the Building With Metal podcast, presented by McElroy Metal, features Kerry Caraway and Rachel Ortiz from Sherwin-Williams discussing paint systems for metal roofing and wall panels. They explain the three tiers of paint systems: polyester (good), silicon-modified polyester/Weather Excel (better), and PVDF/FEVE systems like Floropon and Illumipon (best).

The experts cover how environmental factors, color selection, and project requirements influence paint choice, discussing chalk and fade resistance, primer selection, and geographic considerations. They also explore innovative color technologies, including chameleon colors and wood grain patterns, emphasizing the importance of partnering with paint experts for optimal project outcomes.

  • 53 min

Episode 41 The Art and Science of Metal Paints: Expert Insights From Sherwin Williams

The Building with Metal Podcast – Presented by McElroy Metal

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Notable Quotes

Kerry Caraway: "The first part of the paint system and the most important part of the paint system is the paint resins. And in the paint resin systems and the different paint systems that you have, you have a, just like most things in life, you have a good, better, and best system."

Rachel Ortiz: "We like to think about, are you putting it close to the water? Are you going to put it somewhere where it's desert conditions, where you're always going to have sunny weather? So those things do matter when we're thinking about what type of product to choose, but also what color space to choose."

Kerry Caraway: "We have a test fence down in Fort Myers, Florida that's been there... very long, longer than I've been alive... So we've had panels out there that are 50 plus years old that still retain their color and they are not chalking significantly."

 

What You'll Learn

• Understanding the three-tier paint system hierarchy and how resin quality affects performance and longevity.
• How environmental factors like geography, climate, and UV exposure influence paint system selection and color choices.
• The science behind chalk and fade resistance, including how these are measured and what causes paint degradation over time.
• Why primer selection varies based on application and environmental exposure, including coastal versus inland considerations.
• How color space affects durability, with organic versus inorganic pigments impacting fade resistance and solar reflectivity.
• The role of extensive field testing in paint development and how real-world data drives product recommendations.
• Advanced color technologies including chameleon colors, wood grain patterns, and specialty effects available in modern coil coating.
• Best practices for maintaining and refreshing older buildings while preserving paint warranties through approved cleaning systems.
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Key Timestamps

• [00:00:00] Introduction and guest introductions - Kerry Caraway (Sales Account Manager, 24 years steel industry experience) and Rachel Ortiz (Color Science Department, 7 years at Sherwin Williams)

• [00:03:00] Paint system fundamentals - Three-tier system explained: polyester (good), silicon modified polyester/Weather Excel (better), and PVDF/FEVE systems (best)

• [00:08:00] Color selection considerations - Geographic factors, UV exposure, reflectivity requirements, and architectural versus functional priorities

• [00:12:00] Chalk and fade science - Definition, measurement scales, and how UV breakdown affects paint performance over time

• [00:18:00] Color space impact on performance - Organic versus inorganic pigments, warranty differences for bright colors, and solar reflectivity trade-offs

• [00:26:00] Building maintenance and refresh options - Watts Removal System for cleaning without voiding warranties, approved repaint specialists

• [00:29:00] Geographic and climate considerations - How coastal, desert, and other environmental factors influence paint and primer selection

• [00:31:00] Fort Myers test fence - Thousands of panels tested for decades, hurricane protocols, and real-world performance data collection

• [00:39:00] Advanced color technologies - Chameleon colors, wood grain patterns, Nova effects, and emerging trends in architectural coatings

• [00:46:00] Getting started resources - Sherwin-Williams Coil and Extrusion website, color look books, and expert consultation availability

Mentioned Resources

• Sherwin Williams Coil and Extrusion website
• Fort Myers, Florida test fence facility
• Watts Removal Product (building cleaning system)
• Sherwin Williams Color Lookbook

When you're choosing a metal roof or wall panels, the paint system might seem like just another detail to check off your list. But according to Kerry  Caraway, a Sherwin-Williams account manager with 24 years in the steel industry, it's one of your most important decisions. "The first part of the paint system and the most important part of the paint system is the paint resins," she explains. "And in the paint resin systems and the different paint systems that you have, you have a, just like most things in life, you have a good, better, and best system."

Kerry's journey from corporate procurement manager to paint system expert gives her a unique perspective on what works in the real world. She's seen firsthand how the right paint choice can make or break a project's long-term success.

The Three-Tier System That Makes Sense

Kerry breaks down paint systems into three clear categories that anyone can understand. The "good" level features polyester resin systems that work great for everyday applications like HVAC units, garage doors, and entry doors. These aren't budget options – they're solid performers that get the job done.

Step up to the "better" category and you'll find silicon-modified polyester systems, which Sherwin-Williams calls their Weather Excel line. These are specifically engineered for buildings that face the elements head-on. Think metal buildings and roofing that need to stand up to whatever Mother Nature throws at them.

The "best" tier is where things get really impressive. PVDF and FEVE systems, marketed as Floropon and Illumipon, represent the pinnacle of paint technology. These premium coatings are built for projects where failure simply isn't an option and appearance needs to last decades.

Why Location Matters More Than You Think

Rachel Ortiz, who runs Sherwin-Williams' color science labs in both Texas and Minnesota, has a front-row seat to how geography affects paint performance. Her team handles custom color matching and sees patterns emerge based on the location of buildings. "We like to think about, are you putting it close to the water? Are you going to put it somewhere where it's desert conditions, where you're always going to have sunny weather?" Rachel explains. "So those things do matter when we're thinking about what type of product to choose, but also what color space to choose."

Rachel's dual-lab setup isn't just convenient – it's strategic. Having facilities in both southern and northern climates helps her team understand how different environments affect paint performance. Coastal buildings need enhanced corrosion resistance and thicker primers to fight off salt air. Desert installations face intense UV radiation and sandstorms that can sandblast inferior coatings.

The science behind chalk and fade becomes crucial here. When UV rays break down paint resins over time, you get that chalky white residue that rubs off on your fingers. It's not just unsightly – it's a sign your building's protection is failing. Modern PVDF and FEVE systems resist this breakdown far better than older technologies.

Real-World Testing That Goes the Distance

Kerry loves talking about Sherwin-Williams' test fence in Fort Myers, Florida, and for good reason. "We have a test fence down in Fort Myers, Florida that's been there... very long, longer than I've been alive, actually," she says with a laugh. "So we've had panels out there that are 50 plus years old that still retain their color and they are not chalking significantly."

This isn't just marketing speak – it's serious science. The Florida facility houses thousands of panels that endure hurricane seasons, intense humidity, and relentless sunshine. When storms threaten, teams take down the test panels, let the hurricane pass, then put everything back up. It sounds crazy, but losing decades of performance data would be far worse than the logistical challenge.

Rachel's team uses this real-world data to make recommendations that go beyond lab testing. They've learned that bright, flashy colors often require organic pigments that are less stable than inorganic alternatives. It's a trade-off between eye-catching appeal and long-term performance. Earth tones and neutral colors typically age more gracefully and come with more extended warranty periods.

The color science gets even more complex when you factor in solar reflectivity. Dark colors absorb heat, potentially increasing cooling costs, while highly reflective finishes might create glare issues near airports. It's the kind of detail that separates experienced professionals from well-meaning amateurs.

Innovation That's Changing the Game

Rachel's color science background puts her at the forefront of some fascinating developments. Chameleon colors can shift dramatically as you move around a building – imagine a panel that looks white from one angle but purple from another. Wood grain patterns satisfy the growing demand for natural aesthetics without sacrificing metal's performance advantages.

"Recently I had one where they put wood pieces in the stores, but they wanted the outside of the building to have the similar color as the wood grain," Rachel shares. Her team actually took a piece of real wood and matched its appearance in paint. They've even created finishes that look like corroded metal, protecting the actual metal while achieving a specific aesthetic.

Kerry emphasizes that these advances aren't just about looks. The coil coating industry benefits from technological improvements across the entire supply chain. Steel mills, paint manufacturers, coil coaters, and panel producers are all pushing innovation forward together.

Making Smart Decisions for the Long Haul

Both experts agree that success comes from understanding what you're really trying to accomplish. Kerry's account management approach focuses on matching solutions to actual needs rather than pushing premium products where they're not necessary. Rachel's scientific background helps customers understand the trade-offs involved in their choices.

For buildings that might expand in phases over several years, investing in premium paint systems makes sense. You'll get better color matching when you add that second building five years later. For projects where cost is the primary concern, understanding the performance trade-offs helps you make informed decisions rather than blind compromises.

The maintenance side matters too. Sherwin-Williams partners with companies like Watts Removal Products to offer approved cleaning systems that can refresh a building's appearance without voiding warranties. It's the kind of detail that saves headaches down the road.

As Kerry puts it, "McElroy does such a good job in helping their customers find the right fit for them. They'll come to us, and we'll discuss the problem or the color. They'll go back to their customer, let them know what's going on, and it just makes for the... stream of communication is so important." That partnership approach, whether with McElroy or any quality manufacturer, ensures you get solutions that solve problems rather than create new ones.