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.
There’s a moment at Churchill Downs when the energy shifts. The horses break, the crowd rises, and as the field charges into Turn One, everything feels a little closer, a little louder, a little more real.
It’s one of the most iconic views in sports, and with the recent Turn 1 upgrade, that experience has been elevated in a way that feels both modern and true to the track’s legacy.
What was once a temporary seating area has been transformed into a permanent, premium destination with expanded capacity, covered seating, and thoughtfully designed spaces that bring fans closer to the action. The scale of the project is impressive, but what makes it work day in and day out are the details. The elements people interact with without thinking twice. The features that need to perform just as well on a quiet day as they do when more than 150,000 people fill the venue for the Kentucky Derby.
That’s where AZZ’s role comes into play. As part of the Turn 1 upgrade, AZZ Galvanizing – Plymouth provided hot-dip galvanizing for all of the handrails throughout the space. It’s a focused scope, but an important one. Handrails are constantly in use, exposed to the elements, and expected to maintain both their appearance and integrity over time. In this case, they were finished as part of a duplex system, combining galvanizing with an additional coating layer to deliver both corrosion protection and a consistent, high-quality finish.
The benefit of a duplex system is not just additive, it is synergistic. The galvanized layer protects the steel beneath, while the topcoat extends the life of the system even further, often delivering significantly longer performance than either system alone. For a venue like Churchill Downs, that means fewer maintenance concerns, longer service life, and a better experience for guests year after year.
It’s not the headline feature of the project. Most visitors won’t notice it. But as they move through the space, find their seats, and lean in to catch that first turn, it’s part of what makes the experience feel seamless. At a place defined by tradition, even the smallest upgrades are built to last.
Key Takeaways
AZZ Galvanizing – Plymouth provided hot-dip galvanizing for all handrails in the Turn 1 upgrade
Handrails were finished as part of a duplex system for enhanced durability and appearance
Duplex systems extend service life by combining galvanizing with a protective topcoat
High-touch components like handrails require long-term corrosion protection and performance
Small, often overlooked details play a critical role in the overall fan experience
Hot dip galvanizing is known for its long service life, but there are situations where removing and reapplying the coating is the most practical path forward.