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.
American Galvanizers Association Excellence Awards: Pollinator Pavilion (Civic Contribution Award)
"AZZ – Kansas City" won the Civic Contribution award with “Pollinator Pavilion”. Designed and constructed by students at the University of Kansas School of Architecture, this project stands as an important component of a children’s museum, therefore protecting the steel from corrosion in reach of children was a major safety priority.
Designed and constructed by students at the University of Kansas School of Architecture, this structure acts as a gateway entrance to a prairie on the site of the Kansas Children’s Discovery Center in Topeka, Kansas. The design of the structure stems from the Kansas state bird, the Western Meadowlark, as well as other pollinator species native to Kansas prairies. The incorporation of these elements offers the children visiting the museum a chance to learn about the various pollinators that exist within the prairie. Furthermore, to withstand prescribed burns of the prairie, the entirety of the structure is composed of steel. To ensure this pavilion would remain at the museum for many years to come, the steel structure was specified to be hot-dip galvanized.
This project stands as an important component of a children’s museum, therefore protecting the steel from corrosion in the reach of children was a major safety priority. In addition, galvanizing allows for maximizing structural longevity for future generations to enjoy. This leads to less maintenance during the lifespan of the project. The hot-dip galvanizing finish compliments the lighter aesthetic of the prairie landscape as opposed to the darker finish of an ungalvanized structure.
Compared to alternative coating methods, galvanizing is the best option for addressing the requirements of the Pollinator Pavilion. Hot-dip galvanizing adds a thicker layer of zinc compared to other metallic finishes such as electroplating. This is a necessary step for the outdoor setting as a protective measure against the elements. However, there were challenges that came with galvanizing this project. The largest piece of the structure is composed of welded connections, forming one continuous piece that was much taller than the zinc kettle at the galvanizing plant in Kansas City. This posed the challenge of needing to progressively dip this piece to be sufficiently coated, adding extra steps to the process, and requiring extra attention to detail. Fortunately, the crew at the galvanizing plant were able to help the students achieve optimum coverage of their project.
The result of the hot-dip galvanizing process of the Pollinator Pavilion offers an interactive and educational experience in an environment that caters to the imagination and curiosity of children. By resisting corrosion, the structure will not only be considered safe for the visitors of the museum, but it will also remain present for future generations. Despite the challenges that arose during the process, hot-dip galvanizing proved to be a necessary factor of the project that promises safety and longevity.
Hot-dip galvanizing is a trusted solution for long-lasting corrosion protection, relied upon for its durability and unmatched performance. This video provides a step-by-step look at the galvanizing process, showcasing how steel is transformed with a protective zinc coating that stands up to the toughest conditions. From surface preparation to the final finish, see how this process ensures strength and longevity for projects of all sizes.
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