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.
Design Considerations for Galvanizing: Dissimilar Metals in Contact
When two different metals are in contact in a corrosive environment, one of the metals experiences accelerated galvanic corrosion while the other metal remains galvanically protected.
Hot-dip galvanized steel is well suited for use in a variety of environments and fabrications, and sometimes is placed in contact with different metals including, among others, stainless steel, aluminum, copper and weathering steel.
Metals near each other in the galvanic series have little effect on each other. Generally, as the separation between metals in the series increases, the corroding effect on the metal higher in the series increases as well.
Relative surface areas of contacting dissimilar metals is also relevant in determining which metal exhibits accelerated corrosion. It is undesirable to have a large cathode surface in contact with a relatively small anode surface.
Galvanic corrosion occurs when two different metals are in contact in a corrosive environment: one of the metals experiences an accelerated corrosion rate. The contacting metals form a bimetallic couple because of their different affinities (or attraction) for electrons. These different affinities create an electrical potential between the two metals, allowing current to flow.
The metal higher in the galvanic series of metals, the anode, provides protection for the metal lower in the series, the cathode.
As can be seen from the galvanic series, zinc protects the lower-order steel.
With respect to contacting surface areas of the two metals, although the corrosion current that flows between the cathode and anode is independent of area, the rate of penetration at the anode does depends on current density. Thus, a large anode area in contact with a relatively small cathode area is generally not problematic. Regardless, environmental conditions remain large determinants of corrosion rates.
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.
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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