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.
Corrosion Protection for Water Slides, Pools, and Aquatic Facilities
Pools, waterparks, and aquatic facilities create some of the most challenging environments for exposed steel. Constant humidity, chlorinated water, and frequent wet-dry cycles can accelerate corrosion and shorten the lifespan of unprotected metal components.
Why Aquatic Environments Accelerate Corrosion
For owners and designers, selecting a corrosion protection system that delivers long-term durability while minimizing maintenance is critical to the lifecycle performance of these facilities.
Although swimming pools and waterparks may appear similar to typical freshwater environments, the presence of chlorine and elevated humidity creates unique corrosion conditions.
Chlorinated water contains dissolved chemicals that increase the conductivity of the water, allowing electrochemical corrosion reactions to occur more easily. As water evaporates from pools and splash zones, chlorinated moisture can also settle on nearby steel surfaces. Even when components are not directly submerged, this moisture can contribute to corrosion.
High humidity levels further intensify the problem. Indoor aquatic facilities often operate in warm environments with elevated humidity levels, creating a consistently damp atmosphere that encourages corrosion. Steel surfaces may remain wet for extended periods, allowing corrosion reactions to continue over time.
Frequent splashing and wet-dry cycles also contribute to corrosion. Water slides, wave pools, and splash features continuously expose surrounding structures to moisture, while chemical residues can accumulate on metal surfaces.
Protecting Steel in Aquatic Facilities
Because aquatic environments can be highly corrosive, protective coatings play a critical role in extending the service life of steel components. Coating systems must resist both continuous moisture exposure and the effects of chlorinated water.
Hot-dip galvanizing provides durable corrosion protection for many aquatic facility applications. During the galvanizing process, steel is immersed in molten zinc, creating a metallurgically bonded coating that protects the steel from corrosion.
The zinc coating serves as a barrier between the steel and the surrounding environment while also providing sacrificial protection. If the coating becomes damaged, zinc continues to protect the exposed steel by corroding preferentially to the base metal.
In many aquatic environments, corrosion products that develop on the zinc surface can form a protective scale that slows further corrosion.
Where Galvanized Steel Is Used in Aquatic Facilities
Hot-dip galvanized steel is commonly used throughout pools, waterparks, and aquatic facilities in applications such as:
water slide support structures
pool handrails and ladders
shade structures and architectural steel
maintenance platforms and access stairs
fencing and perimeter structures
equipment supports and utility structures
These applications benefit from the durability of galvanized coatings, particularly in environments where frequent maintenance or repainting may be difficult.
Designing for Long-Term Durability
In addition to selecting appropriate coatings, proper design practices can help extend the lifespan of steel in aquatic environments.
Allowing for proper drainage and avoiding areas where water can collect are important design considerations. Steel components should also be designed to promote airflow and allow moisture to evaporate whenever possible.
In some cases, duplex coating systems that combine galvanizing with paint or powder coating may be used to provide additional corrosion protection in particularly aggressive environments.
Aquatic Facility Projects Using Galvanized Steel
Several aquatic facilities have successfully used galvanized steel to provide durable corrosion protection in high-moisture environments.
The Northside Swim Center incorporates galvanized structural steel throughout the aquatic complex, helping protect exposed steel components from continuous moisture and splash exposure.
At Camp Barnabas, galvanized steel supports accessible aquatic recreation features designed for durability and minimal maintenance in an outdoor water environment.
These projects demonstrate how galvanized steel can provide reliable corrosion protection in facilities where moisture, chemicals, and heavy use place significant demands on structural materials.
Long-Term Performance in Aquatic Environments
Aquatic facilities require materials capable of withstanding constant exposure to moisture, chemicals, and fluctuating environmental conditions. By selecting durable corrosion protection systems and designing structures with long-term performance in mind, project teams can help ensure steel components remain safe and reliable for decades.
Hot-dip galvanized steel continues to provide dependable corrosion protection in many aquatic applications, helping pools and waterparks maintain the structural durability required to support safe and enjoyable recreational environments.
At AZZ Galvanizing and Plating – Milwaukee, precision and performance come together to deliver reliable corrosion protection and surface finishing solutions.