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: Schomp Automotive Group – “Hail No” (Original Equipment Manufacturing Category)
"AZZ Galvanizing - Denver" played a vital role in protecting the columns that support an innovative anti-hail netting system in use on Colorado's Front Range.
Extreme hailstorms are occurring with both more intensity and frequency than just a couple decades ago. While scientists debate why these storms are different today, no one argues with their catastrophic effects.
The damage from a hailstorm can be devastating to any residential and business properties in its path. The United States experienced that largest single insured loss event in May of 2014 when a system of severe storms rained hail sporadically over a 5-day stretch causing heavy and damage and destruction from Colorado to Pennsylvania with insured losses exceeding $2.9 billion.
Colorado’s most damaging hailstorms generally occur between mid-April to mid-September, with the Front Range located in the heart of what’s now called “Hail Alley”. Colorado residents and businesses can count on three or four catastrophic (defined as at least $25 million in insured damage) hailstorms every year. The past 10 years have been brutal for Colorado, eclipsing more than $5 billion in losses, and that’s just the insured damage.
Few businesses have more exposure to these storms than new car dealerships, with car and truck inventories values into the tens of millions sitting exposed in the parking lot. A major dealership can lose a large percentage of the inventory in just a single storm. In some cases, these late model cars can incur damage that’s beyond the value of the vehicle. It’s not uncommon the numbers of damaged cars and trucks exceeds the available resources for timely repairs, leaving the decision makers with few options beyond liquidation of the damaged vehicles at a fraction of the original value.
Insurance companies have taken notice and believe this new breed of hailstorms is here for the future. Some insurers are refusing to cover dealerships (especially along the Front Range) due to the increased odds for hail damage. Others are charging rates several times higher than just a few years ago. This has left the dealerships with few avenues beyond paying these exorbitant rates while waiting to see which company will be unlucky enough to experience that aftermath of the next big storm.
Schomp Automotive Group decided on a different course of action. Rather than just waiting and watching the skies, the designers at Schomp Automotive Group began to develop a system to mitigate the hailstorm threat. In 2021, Shomp began to construct a hail-net system called “Hail No” to protect their exposed car inventory. This creative design uses large 10″ and 12″ diameter steel tube columns set in concrete to support a strong netting system with spans as long as 63′, capable of supporting up to a foot of snow. The netting system is designed to be easily taken down and stored for the winter months when snowstorms can occasionally exceed the “Hail No” system load capacity.
The hot-dip galvanizing coating was selected for its sustainability and much smaller carbon footprint than any of the other protective coating options, which would require periodic maintenance or recoating intervals every five to fifteen years. Hot-dip galvanizing has a proven track record for providing decades of maintenance free protection from corrosion. These more destructive hailstorms will be no match for the hot-dipped galvanized steel columns. The zinc and iron alloy layers that form on the steel during the galvanizing process are harder than the base metal it covers, thus providing added strength and additional protection from impact damage that would compromise other protective coatings.
Another important consideration was the fact that the hot-dip galvanizing process coats all surfaces internal and external, providing equal protection on the inside of these hollow columns. The internal galvanizing coating ensures that there are no opportunities for unseen, internal corrosion to set in. The Hail No protection system was truly designed to last a lifetime and beyond.
Insurance companies are buying in with the new “Hail No” system by lowering insurance rates as much as 40-50 percent for the vehicles protected by the new netting system. That’s enough saving to pay for the system within just a few years. Dealership interest is certainly growing along the Front Rage as well as outside the region with several dealerships making plant to invest in the “Hail No” or similar system to mitigate the hailstorm concern.
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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