Once the metal is cleaned, treated, and painted, the strip is rewound into a coil size prescribed by the customer. From there, the coil is removed from the line and packaged for shipment or additional processing.
After the primer is applied and cured, then the metal strip enters the finish coat station where a topcoat is applied. Topcoats provide color, corrosion resistance, durability, flexibility and any other required physical properties. Like primers, the topcoat is cured using thermal cure ovens.
Oven
Coil coating ovens can range from 130 feet to 160 feet and will cure the coatings in 13 to 20 seconds.
During this stage, the strip enters the prime coat station whereby a primer is applied to the clean and treated metal. After the primer is applied, the metal strip travels through a thermal oven for curing. Primers are used to aid in paint adhesion, improve corrosion performance and enhance aesthetic and functional attributes of the topcoat.
S Wrap Coater
The S wrap coater design allows for primers and paints to be applied to the top and back side of the metal strip simultaneously in one continuous pass.
The cleaning and pretreating section of the coil coating process focuses on preparing the metal for painting. During the cleaning stage, dirt, debris, and oils are removed from the metal strip. From there, the metal enters the pretreatment section and/or a chemical coater whereby chemicals are applied to facilitate paint adhesion and enhance corrosion resistance.
Dried-In-Place
In this stage a chemical that provides enhanced corrosion performance is applied. This treatment can be chrome free if required.
The accumulator is a structure that adjusts up and down to store material, which makes continuous operation of the coil coating process possible. This accumulation will continue to feed the coil coating processes while the entry end has stopped for the stitching process. As much as 750 feet of metal can be collected.
The American Galvanizers Association recognized the SmogStop Highway Purification Wall for combining environmental innovation with durable galvanized steel infrastructure.
Infrastructure projects are increasingly being challenged to do more than simply serve a functional purpose. The award-winning SmogStop Highway Purification Wall project is a prime example of how modern infrastructure can combine engineering, sustainability, and durability into a single innovative solution.
Recently recognized with a 2026 Excellence in Hot-Dip Galvanizing Award from the American Galvanizers Association, the SmogStop project transformed a traditional highway sound barrier into an active air purification system designed to help improve air quality along a busy transportation corridor in Ontario.
AZZ is proud that the galvanizing work for this groundbreaking project was completed by AZZ Galvanizing โ Acton.
Unlike conventional sound barriers, the SmogStop system incorporates a double-walled aerodynamic design that channels vehicle emissions through an internal cavity. Inside the system, photocatalytic coatings activated by sunlight work to break down pollutants such as nitrogen oxides (NOx) and volatile organic compounds (VOCs) into less harmful substances.
The project demonstrates how infrastructure can move beyond passive functionality to actively support environmental improvement.
While the environmental innovation attracted significant attention, long-term durability was equally important to the projectโs success. Highway infrastructure must withstand constant exposure to moisture, road salt, freeze-thaw cycling, airborne contaminants, and traffic vibration. In these harsh conditions, corrosion protection becomes critical to ensuring reliable long-term performance while minimizing maintenance demands.
Hot-dip galvanizing provided the durable corrosion protection needed for the steel support structure throughout the installation. AZZ Galvanizing โ Acton processed the galvanized steel components supporting 88 full-length purification panels totaling approximately 8,843 square feet and roughly 84,000 pounds of panel weight, along with 54 galvanized steel support posts.
The project stood out to judges not only because of its innovative environmental focus, but also because it highlighted galvanized steel as a key contributor to sustainable infrastructure. By pairing advanced air purification technology with the long-term performance benefits of hot-dip galvanizing, the SmogStop project demonstrated how durable steel infrastructure can support broader environmental goals.
Projects like SmogStop continue to showcase the evolving role of galvanized steel in modern infrastructure applications. From transportation systems and utility structures to architectural landmarks and environmental technologies, hot-dip galvanizing remains a proven solution for projects requiring longevity, resilience, and reduced lifecycle maintenance.
Congratulations to the team at AZZ Galvanizing โ Acton for their contribution to this award-winning project and for helping support infrastructure innovation that looks beyond todayโs challenges toward a cleaner future.