Your project is going smoothly — no major hiccups, no delays, no material problems. But when the work is done, there’s a glaring error —the color isn’t consistent across the roof. It looks like tiger stripes across the panels. The building owner notices it too, and now they want you to redo the installation to get the consistent color that they chose from the start. You have to eat into your profits, order new materials, and redo installation to meet the requirements of the project.
This is a potential problem for metal roofing contractors working with coils that come from multiple batches of paint. If you don’t take the time to understand which colors not to mix from different batches, then you could end up with a project that may end up costing you money out of your own pocket.
In this article, we’ll look at the common issues that come from mixed paint batches, and five ways to avoid color mixing problems when it comes to metal roofs.
What Is a Visual Match Color?
Metal roof paint colors contain pigments that give the paint its unique color. Nowadays, colors are analyzed at paint lines using sophisticated imaging equipment to measure samples. This works for some colors, but others with organic pigments or unique pigment formulations – such as metallics – are harder to measure consistently by a computer.
A visual match color is a color that can’t be matched perfectly using automated equipment. These colors have to be matched manually, by eye, on the paint line to ensure consistency. And even then, subtle shifts can occur in hues from one paint run to the next.
If you use visual match colors from multiple batches on your project, then you could have problems.
Which Colors Should Not be Used in Mixed Batches?
Metallics — colors like silver metallic or copper tones — contain mica flakes or aluminum particles, which shift in appearance depending on the viewing angle. Metallics are the most difficult to match and should never be used in mixed batches. Contractors must install all metallic panels in the same direction to retain consistency in varying lights. Some suppliers like Sheffield Metals will have arrows on the backs of metallics to show which direction to install them.
Vibrant colors —like reds as well as certain white and black shades, contain rich, organic pigments and may be less consistent from batch to batch. You should ask your supplier about using mixed batches for these colors.
Natural, dull colors like standard browns, bronzes, and other earth tones are made using stable inorganic pigments and typically stay consistent across paint batches.
Common Problems Due to Using Mixed Batches
Patchy, Mismatched Design
If you use mixed paint batches with visual match colors, you may have a patchy, mismatched design, or the roof will have “tiger stripes” varying in hues on panels across the roof.
The mismatched look will be obvious to you and the home or building owner. These colors may fade differently and have different gloss levels, which can hurt aesthetics and also pose problems regarding the paint warranty.
Rejected Work and Project Delays
If the roof is tiger-striped, the owner most likely will reject the work and demand a new installation. You’ll have to complete the work by eating into your own profits. This will probably include a tear-off of the entire roof and finding a new visual match that’s consistent.
Profit Erosion and Reputational Damage
If you don’t take the time in the beginning to make sure you have visual color matches, then it could cost you time and money later on —expanded timelines, reduction of profits, and not to mention the impact it will have on your reputation in the metal roofing industry.
Installation horror stories have a way of getting around, and if you end up with a home or building owner who’s dissatisfied with the final project, it could hurt you in the future.
5 Ways to Avoid Color Mixing Problems
1. Produce Full Panel Runs from the Same Batch of Paint
The easiest way to have consistent color matching over a roof is to produce all the panels from the same paint batch. Obviously, this won’t be possible for some projects. If you do have to use different batches, then use one batch on one plane of the building, and the other batch on the opposite side. If there are inconsistencies between the colors, the differences will be masked better since the batches will be on different sides, with different angles in the light.
2. Don’t Use Leftover Materials
Even if it looks like old materials match the color of your current project, it’s never a good idea to mix these with new orders. For visual match colors, the differences will become apparent soon when they’re up on the roof.
3. Don’t Mix Paint Systems
Even if two colors have the same name, they could belong to different paint systems — such as SMP or PVDF. They could have a different gloss, or one may be textured while another isn’t. All of these small differences can have huge effects on how a color ages over time and how it will look. If you’re unsure whether a color is a true match, ask your metal roofing supplier.
4. Double Check Panels
Metal roofing manufacturers will put visual match labels on coils. Check what coils you’re using and eye-match the panels in different lights to ensure you have consistency.
5. Make Sure You Order Enough Material from the Start.
Calculate your waste and give yourself a buffer when it comes to material. If you run short, your supplier might not be able to provide extra material from the same paint run.
6. Talk to Your Supplier
If you’re uncertain about the colors you’re using, check in with your metal roofing supplier. If they’re a good supplier, they’ll have the coils labeled and know what batches the metal came from.
Need Support for Your Metal Roofing Project?
Working with mixed paint batches is a technical process, and if you aren’t certain how it works, you could be left eating into your profits and delaying timelines. Make sure you’re working closely with your supplier to understand what’s safe to mix, and best practices for making sure you don’t end up with a mismatched roof.
Contact the Sheffield Metals team today to get support, or check out related content from the Metal Roofing Learning Center below:
Should You Repaint a Metal Roof? Considerations and Best Practices – Sheffield Metals
PVDF vs. SMP Paint Systems: Which Is Best For Your Metal Roof?
