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.
Spin galvanizing is a hot-dip process that utilizes a centrifuge anchored to a galvanizing kettle (or a spinner located above it) for immersing small to medium scale components in molten zinc. A tightly bonded alloy coating forms on the steel, providing long-term, durable protection from the devastating effects of corrosion, while the centrifuge or spinner removes excess molten zinc to ensure coating uniformity, quality fit, and precise functionality.
AZZ is pleased to bring state-of-the-art spin galvanizing capabilities to our AZZ Galvanizing-Houston location. We are operational and equipped to serve a broad range of customers – and, for added convenience, transportation to and from D/FW, San Antonio, Austin, Waco, Baton Rouge and the Beaumont Golden Triangle!
AZZ’s Spin Galvanizing Process Delivers:
• 100% complete and consistent coverage • Cathodic protection • 3,600 psi coating bond strength • Hardness – difficult to damage during tightening • Temperature range: continuous exposure in arctic climates to the extremes of 392°F • Paintable – prepared according to ASTM D 6383
To learn more about our capabilities in Texas, please call our plant directly or complete our online contact us form today!
AZZ Galvanizing – Houston
7407 C E King Pkwy Houston, TX 77044 Phone: 281.458.1550
Powder coating your critical components offers a variety of benefits in terms of performance, long-term cost savings, and more, and AZZ has an expansive network of powder coating facilities ready to help you take advantage.
We have the experience and tools you need to realize those decorative and functional benefits, and that network helps us do it without vast turnaround times you’ll experience with smaller operations.
Powder Coating: A More Durable, Protective Option
Powder coating provides:
Corrosion Resistance Chemicals and moisture can eat away at metals like steel, but powder coating provides key resistance against those elements by acting as a barrier that prevents corrosion.
Chemical Resistance Depending on a finished product’s unique application, oils, gasoline, harsh cleansers and much more can come into contact with finished solution. Powder coating helps parts resist the negative effects of these chemicals.
Electrical Insulation Resistance Powder-coated components can be specifically designed and tested for use on electrical components, helping ensure safety and performance.
Heat Resistance While in use, coatings can face elevated temperatures either constantly or during intermittent use, and powder coating can help finished products stand up to those harsh environment factors in applications from residential barbecues to automotive engines and beyond.
Abrasion, Impact and Marking/Mar Resistance Powder coating is known for its durability in the face of forces that would wear it down, cause damage due to significant impact or mark the coating with scratches or other marring. Not only does this maintain the coating’s integrity and resistance to other elements – it also helps maintain an attractive finish for longer durations of use.
Powder-coated parts are also attractive, with consistent, quality finishes that stand the test of time and make parts stand out.
AZZ’s Flexibility in Powder Coating
AZZ has facilities that can powder coat everything from the smallest parts to parts up to 60 feet in length, offering tremendous flexibility in meeting all of your powder coating needs.
AZZ has also earned the following certifications in heavy equipment, aerospace and defense, and more:
AS9100
Caterpillar
General Dynamics
ISO 9001
NADCAP Quality
PACCAR
We back our versatility and experience with a commitment to a durable, long-lasting and attractive finish. To learn more, visit azz.com/powder-coating .
The airport represents the vibrant culture of New Orleans while being mindful of the economic and environmental impact of this large infrastructure project. With the need to uphold safety standards and ensure the construction was geared toward protecting the long-term investment and lifespan of the structure, designers utilized hot-dip galvanizing (HDG).
The project was completed by AZZ Galvanizing – Morgan City, applying AZZ’s extensive experience and expertise in hot-dip galvanizing to deliver a truly stunning, high-performance result.
For its efforts, this tasteful and carefully thought out airport recently won the American Galvanizers Association (AGA) Artistic award.
About the Piece
Louis Armstrong New Orleans International Airport’s design was inspired by the geography of the Delta region. The building curves like the Mississippi River with the use of arches, columns and glass facades. The use of glass windows creates a terrific view of the airfield and the surrounding outdoors. The Mississippi River is brought to life through the designed created with hot-dip galvanized steel and painted in a duplex system that will leave the design protected for many years to come.
Why the Designer Chose Hot-Dip Galvanizing
The designers chose hot-dip galvanizing because of its sustainability and ability to meet the requirement of a 50-year life with a low maintenance cost. The airport designers wanted minimal upkeep to reduce the amount of delays on the tarmac. Hot-dip galvanizing is durable and will reduce the risk of erosion caused by humid Louisiana weather and the harshness of everyday airport traffic.
The project engineer, who is a LEED® professional DBE, remarked that the initial cost of hot-dip galvanizing was more economical than the high-performance coatings available to the steel industry today. Hot-dip galvanized steel addresses the economic and cultural factors that will make the airport project successful well into the future.
Project Recap
Louis Armstrong New Orleans International Airport won the American Galvanizers Association (AGA) Artistic award because of their innovative and sustainable design using hot-dip galvanizing (HDG). Hot-dip galvanizing offers the necessary protection from the abrasiveness of the day-to-day airport operations. The product was also cost effective, making HDG the right coating for MSY.
AZZ focuses on creating a stronger, safer world, evidenced by our focus on protecting infrastructure from corrosion. This project was an innovative way to show the possibilities of galvanizing. Learn more about AZZ’s capabilities by exploring our hot dip galvanizing capabilities.
When the decision is made to hot-dip galvanize, it is important to consider all aspects of the project, down to the smallest hole. Because hot-dip galvanizing is a coating of zinc on bare steel, the original steel becomes slightly thicker. Typical galvanized coatings range from 3-8 mils (75-200 microns). When designing and detailing tapped holes, the increased thickness is important.
Hole sizes in certain fabricated steel products must be oversized to account for the zinc that bonds to the edges. If after galvanizing the hole is still not large enough, it can be retapped. Retapping will not necessitate regalvanizing. Because of the zinc coatingÂ’s cathodic properties, the coating on the mating fastener will protect chased or retapped nuts.
For holes that will be threaded after galvanizing, the hole should be drilled undersize before galvanizing so the threads can be cut after galvanizing.
Clearance holes must be designed to account for zinc pickup. Oversizing holes according to ASTM guidelines is usually sufficient to account for the thickness of the zinc coating.
Threaded assemblies must adequately accommodate galvanized fasteners. It is important to make sure the hole is undersized enough so that when cutting the threads, all zinc is removed and the hole is still accurately sized. If all of the zinc is not removed from the threaded hole, its relatively soft structure may become damaged when fitting the hole with a fastener. It is best to mate a galvanized fastener with threads solely composed of steel to ensure a quality bolted connection. When threads have been cut it will expose bare steel, but utilizing a hot-dip galvanized fastener in the threaded hole will cover the bare steel and give protection from corrosion for the bolted connection.
Uncoated fasteners should never be put in a galvanized threaded hole. ZincÂ’s cathodic protection characteristics cause it to sacrifice itself to protect the uncoated fastener, accelerating the rate in which zinc is consumed.
Minimize the use of very small holes that may become completely obscured by zinc. If small holes are unavoidable and become filled with zinc, the area may be heated after galvanizing in order to remove the excess zinc and open the hole.
Design considerations courtesy of American Galvanizers Association. The AGA also has the publication, The Design of Products to be Hot-Dip Galvanized After Fabrication, available for download.Â
The simple answer is that almost anything on a farm or other agriculture operation can utilize galvanized steel. It can be used for stronger tractor parts, trailers, irrigation systems, fencing, tools, animal pens, barns, storage facilities, and more. Just about anything that sees heavy use, especially in an outdoor environment, can and should benefit from the power of galvanized steel.
At Cherry Creek Systems, the company works closely with customers to design and execute custom systems for greenhouse applications, using hot-dip galvanization to protect versatile, but hollow, steel tubing that brings strength to these systems. Galvanized solutions are also hygienic for use around animals and protect hollow parts and equipment in other areas of agricultural operations, such as conveyor castings, chains, supports, storage racks, irrigation equipment, refrigeration components to stand up to frigid temps and condensation, and much more.
In Agriculture, It’s Not Just Rust that Threatens Equipment
Other than the ever-present threat of rust and corrosion, equipment is exposed to other dangers, as well. Powerful storms and gusting winds fling debris at structures, machinery and fences, causing dents and more serious damage. Frequent use of equipment causes wear and tear, and extreme or changing temperatures can be dangerous, as well. The toughened zinc alloy coating of galvanized steel protects it from all of these things, repelling debris, shielding from abrasions, and maintaining overall structural integrity through the most extreme conditions.
Protecting the Budget
At first glance it might seem like all this extra protection makes galvanized steel a much more expensive investment than regular steel. However, not only is galvanized steel comparably priced, it also saves money down the road. The sturdiness of galvanized steel means it doesn’t need repairing or maintaining as often as other materials. That means less money spent on repairs and less downtime caused by maintenance. The abrasion-resistant surface makes it easier to clean and paint, and the rust-proof nature means it can go decades without needing to be replaced or patched up.Â
Toughen UpÂ
Everybody should be aware of what they’re getting when choosing the best tools for the job. In almost every case, those tools are made with galvanized steel. The agriculture life will always be tough, but there’s no reason that equipment shouldn’t be up to the task.
