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.
Galvanized reinforcement, which has a longer history in reinforced concrete than any other technology on the market, witnessed very little change until the introduction of (ASTM A1094) Continuous hot-dip galvanized rebar. Accordingly, research is underway at Texas A&M University National Corrosion and Materials Laboratory to determine the recent innovation’s performance compared to traditional reinforcement solutions.
Researchers have completed phase 2 of testing corrosion performing materials used in reinforced concrete, including Hot-Dip galvanized (ASTM A767), Continuously Hot-Dip Galvanized (ASTM A1094), Epoxy Coated CGR (ASTM A1055), continuously galvanized MMFX (ASTM A1035/ ASTM A1094) and bare steel (ASTM A615).
The study examined durability aspects of these coatings and will observe longevity of concrete reinforced elements (Figure 1).
Figure 1.
The first two phases of the report explore how the baseline galvanized coatings (A767, A1094 and CG A1035) perform. Methodology for each phase is summarized below:
Research Phase 1: Establishing a corrosion baseline
The NACE standard 0290 was used to establish a corrosion baseline rate for bare (615) steel and cathodically (767, 1035, 1094) protected steels (Figure 2). A 100 mV or more negative difference between bare steel and galvanized steels demonstrates the effectiveness in providing sacrificial protection to the reinforcing steel. The three samples identified are all providing comparable sacrificial corrosion protection well below (more negative=better) the cathodic protection limit.
Figure 2.
Research Phase 2: Impedance results of galvanized coatings
A very effective way of measuring corrosion performance of a coating is Electrochemical Impedance Spectroscopy (EIS). EIS measurements provide reliable data, allowing for the prediction of the long-term performance of the coatings (Figure 3). The result of EIS is the impedance of the electrochemical system as a function of frequency. Essentially, impedance testing provides an overall corrosion resistance of a coating system including electrolyte resistance, coating resistance, and charge transfer resistance of the metallic substrate.
Figure 3.
The 30-day testing reveals that the 767 specimens exhibited the lowest impedance values among the galvanized specimens. Results indicate that although this coating provides sacrificial cathodic protection, it is likely that the zinc corrosion products formed as a result of the anodic dissolution of zinc are less protective than the corrosion products formed on the 1094 specimens.
The higher corrosion or dissolution rate on the Zn layer will have less durability in terms of sacrificial protection effect. (i.e. 767 specimen will have a higher corrosion or dissolution rate, and the galvanized layer will have less life expectancy based on the current results). While comparable, it is evident that the consistent thick layer of pure zinc (1094) is providing more protection than a thicker zinc-iron alloy coating structure (767).
Continuous hot-dip galvanized rebar just performs better!
Early findings conclude galvanized rebar has the longest demonstrated life for coated products regardless of what specification is used for the design of concrete reinforced elements. The innovative processing and adaptability of GalvaBar lends itself to other longer life products, including: epoxy coated (ASTM A1055), used for Grade 65 and high strength thread-bar, smooth dowels and all grades of MMFX/ (ASTM A1035).
The test results are extremely positive and it’s clear that zinc protects steel no matter what product is selected for galvanized rebar. With GalvaBar, however, customers also receive the benefit of galvanized rebar that is processed prior to fabrication and the availability of a consistent, high quality product already available in the supply chain.
E-coating is an industrial paint process providing total paint coverage for the part, including areas that are typically inaccessible to other types of spray applications. The automated process ensures a precise, evenly deposited film and superior finish with comprehensive corrosion protection.
Strong quality control with fast turnaround times
A division of AZZ, North America’s largest hot-dip galvanizer of fabricated metals, we have a significant operating footprint and state-of-the-art facilities, which make us well equipped for large-scale production and fast turnaround times. Extensive experience and strong quality control enable us to meet the stringent standards of the many industries we serve, earning us the following certifications and accreditations:
AS9100 (aerospace quality management)
Caterpillar (heavy equipment)
General Dynamics (aerospace and defense)
ISO (quality management)
NADCAP Quality (aerospace and defense)
PACCAR (automotive)
With highly automated operations and extensive expertise, we are equipped to meet your production demands, ensuring fast turnaround times and on-time deliveries.
Capacity and capabilities to meet all your production needs
Our state-of-the-art, highly automated powder coating operations are equipped to accommodate parts measuring less than an inch to components up to 60 feet in length and meet high-volume production needs with turnaround times as short as 24 hours and consistent on-time delivery.
Utilization of the combination of conveyor and batch lines enables us to powder coat an array of components, including stampings, castings, extrusions, and tubing, all of which are processed through a three-stage or five-stage iron phosphate washer and are hand-washed as required to achieve a comprehensive, durable, and flawless finish.
A commitment to quality that meets the highest of standards
AZZ’s ISO 9001 certified processes and unwavering focus on zero defects enable us to meet the most stringent quality standards of the many industries we serve, earning us the following certifications:
AS9100 (Aerospace)
Caterpillar (Heavy Equipment)
General Dynamic (Aerospace and Defense)
ISO (Quality Management)
NADCAP Quality (Aerospace and Defense)
PACCAR (Automotive)
For high-quality powder coating that provides durable and decorative corrosion protection and meets your most demanding production requirements, AZZ Surface Technologies has you covered.
AZZ Surface Technologies offers a wide range of high-quality metal finishing services to protect and extend the life of application-critical components. Our extensive capabilities, which include powder coating, plating, e-coating, wet coating, duplex coating, military specification coatings, and sand blasting surface preparation, offer comprehensive corrosion protection solutions for metal parts and components ranging in size, design, and function.
Large-scale production with fast turnaround times
A division of AZZ, North America’s largest hot-dip galvanizer of fabricated metals, we have a significant operating footprint and state-of-the-art facilities which make us well equipped for large-scale production and fast turn-around times. Extensive experience and strong quality control enable us to meet the stringent standards of the many industries we serve, earning us the following certifications and accreditations:
PACCAR (automotive)
NADCAP accreditation (aerospace and defense)
ISO certification for quality management
AS9100 certification (aerospace)
We function like our operation is in your facility
Committed to being even more than a leading provider of high-quality metal finishing services, we are a collaborative supply chain partner which functions as if we are located within your production facility to significantly increase operational efficiencies, reduce your logistics costs, and make it easy to do business with us. AZZ is the supply chain partner who has you covered.
You’ve done your research. You’ve evaluated the price, finished product, overall look and more of both liquid-paint and powder-coat options, and you’d likely consider your dive into the topic done and dusted. After all, you’ve found the best solution for your bottom line. However, have you considered the environmental impact of both options? Do you know which is better for the planet and which might align more directly with your ethics as a business? Let’s take a look.
Liquid Paint vs. Power Coating: The Tale of the Tape
While powder coating is more durable than liquid paint, the benefits of utilizing the process extend far beyond that. Powder coating is safer on several levels, both personal and environmental. In fact, the Environmental Protection Agency (EPA) recommends powder coating as a sustainable coating option. Wet paint storage, especially when handled improperly, can lead to dangerous fires that are harmful for both workers and the environment. Wet paint is also unhealthy for those who work with it on a daily basis. However, the environmental implications of wet paint should also be considered. As it evaporates, liquid paint lets off volatile organic compounds, known as VOCs. VOCs not only lead to personal health issues like respiratory illness but are a tremendous source of industrial-based pollution and ozone damage. Chrome-based primers necessary when painting aluminum is also eliminated with the use of powder coating, which often requires no primer at all. In contrast, the powder-coating process doesn’t contain any liquids, thus avoiding any evaporation-related headaches. Waste associated with powder coating is also not directly hazardous to the environment, leading to easier disposal. There’s less overall waste, as well – overspray associated with powder coating can be reused and recycled, providing up to a 97% utilization rate from a box of powder. Liquid paint can’t be reclaimed in the same way. Powder coating is also safer for those completing the application as long as appropriate precautions are taken to ensure the powder isn’t inhaled or coming into direct contact with skin.
The Choice is Clear
While powder coating should likely already be your coating method of choice due to the benefits it provides in saving costs and lasting longer, its lower environmental impact is yet another way that the process is a step ahead of liquid-paint-based processes. At AZZ, we have an expansive network of powder-coating facilities with state-of-the-art, highly automated operations that enable quick turnaround and further promote environmental and personal benefits. Our powder-coating process is also ISO 9001 certified, and we’ve developed an industry-leading reputation for durable, attractive and long-lasting finishes for items ranging from small parts to items up to 60 feet in length. We’re also committed to sustainability that goes beyond the built-in benefits of powder coating. We also utilize 100% naturally occurring zinc in our hot-dip galvanizing process, part of a wholly recyclable process that involves no VOCs.
If you’re ready to up your commitment to environmentally sustainable coating options, contact us today at azz.com/request-more-information.
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