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.
Capacity and capabilities to meet all your production needs
Our state-of-the-art, highly automated powder coating operations are equipped to accommodate parts measuring less than an inch to components up to 60 feet in length and meet high-volume production needs with turnaround times as short as 24 hours and consistent on-time delivery.
Utilization of the combination of conveyor and batch lines enables us to powder coat an array of components, including stampings, castings, extrusions, and tubing, all of which are processed through a three-stage or five-stage iron phosphate washer and are hand-washed as required to achieve a comprehensive, durable, and flawless finish.
A commitment to quality that meets the highest of standards
AZZ’s ISO 9001 certified processes and unwavering focus on zero defects enable us to meet the most stringent quality standards of the many industries we serve, earning us the following certifications:
AS9100 (Aerospace)
Caterpillar (Heavy Equipment)
General Dynamic (Aerospace and Defense)
ISO (Quality Management)
NADCAP Quality (Aerospace and Defense)
PACCAR (Automotive)
For high-quality powder coating that provides durable and decorative corrosion protection and meets your most demanding production requirements, AZZ Surface Technologies has you covered.
AZZ Surface Technologies offers a wide range of high-quality metal finishing services to protect and extend the life of application-critical components. Our extensive capabilities, which include powder coating, plating, e-coating, wet coating, duplex coating, military specification coatings, and sand blasting surface preparation, offer comprehensive corrosion protection solutions for metal parts and components ranging in size, design, and function.
Large-scale production with fast turnaround times
A division of AZZ, North America’s largest hot-dip galvanizer of fabricated metals, we have a significant operating footprint and state-of-the-art facilities which make us well equipped for large-scale production and fast turn-around times. Extensive experience and strong quality control enable us to meet the stringent standards of the many industries we serve, earning us the following certifications and accreditations:
PACCAR (automotive)
NADCAP accreditation (aerospace and defense)
ISO certification for quality management
AS9100 certification (aerospace)
We function like our operation is in your facility
Committed to being even more than a leading provider of high-quality metal finishing services, we are a collaborative supply chain partner which functions as if we are located within your production facility to significantly increase operational efficiencies, reduce your logistics costs, and make it easy to do business with us. AZZ is the supply chain partner who has you covered.
You’ve done your research. You’ve evaluated the price, finished product, overall look and more of both liquid-paint and powder-coat options, and you’d likely consider your dive into the topic done and dusted. After all, you’ve found the best solution for your bottom line. However, have you considered the environmental impact of both options? Do you know which is better for the planet and which might align more directly with your ethics as a business? Let’s take a look.
Liquid Paint vs. Power Coating: The Tale of the Tape
While powder coating is more durable than liquid paint, the benefits of utilizing the process extend far beyond that. Powder coating is safer on several levels, both personal and environmental. In fact, the Environmental Protection Agency (EPA) recommends powder coating as a sustainable coating option. Wet paint storage, especially when handled improperly, can lead to dangerous fires that are harmful for both workers and the environment. Wet paint is also unhealthy for those who work with it on a daily basis. However, the environmental implications of wet paint should also be considered. As it evaporates, liquid paint lets off volatile organic compounds, known as VOCs. VOCs not only lead to personal health issues like respiratory illness but are a tremendous source of industrial-based pollution and ozone damage. Chrome-based primers necessary when painting aluminum is also eliminated with the use of powder coating, which often requires no primer at all. In contrast, the powder-coating process doesn’t contain any liquids, thus avoiding any evaporation-related headaches. Waste associated with powder coating is also not directly hazardous to the environment, leading to easier disposal. There’s less overall waste, as well – overspray associated with powder coating can be reused and recycled, providing up to a 97% utilization rate from a box of powder. Liquid paint can’t be reclaimed in the same way. Powder coating is also safer for those completing the application as long as appropriate precautions are taken to ensure the powder isn’t inhaled or coming into direct contact with skin.
The Choice is Clear
While powder coating should likely already be your coating method of choice due to the benefits it provides in saving costs and lasting longer, its lower environmental impact is yet another way that the process is a step ahead of liquid-paint-based processes. At AZZ, we have an expansive network of powder-coating facilities with state-of-the-art, highly automated operations that enable quick turnaround and further promote environmental and personal benefits. Our powder-coating process is also ISO 9001 certified, and we’ve developed an industry-leading reputation for durable, attractive and long-lasting finishes for items ranging from small parts to items up to 60 feet in length. We’re also committed to sustainability that goes beyond the built-in benefits of powder coating. We also utilize 100% naturally occurring zinc in our hot-dip galvanizing process, part of a wholly recyclable process that involves no VOCs.
If you’re ready to up your commitment to environmentally sustainable coating options, contact us today at azz.com/request-more-information.
Durable protection for parts measuring less than an inch to components up to 60 feet in length
Comprehensive coverage for complex and detailed designs
An array of color and texture options for aesthetics and compliance with safety codes
Protection strong enough for the defense industry
AZZ is a leading provider of chemical agent resistant coatings (CARC) meeting military specifications and providing the highest level of protection against radioactive, chemical, and biological warfare agents for large format and heavy equipment parts.
Sandblasting surface prep
With extensive expertise in sandblasting, AZZ provides the surface preparation critical for a high-quality, consistent finish for parts ranging in size up to 40 feet in length.
Large-scale production and fast turnaround capabilities
AZZ’s North American network of state-of-the-art, highly automated facilities enables us to integrate seamlessly into your supply chain and provides the capacity and fast turn-around times to meet your most demanding production schedules with consistent, on-time delivery.
Using the AGA Life-Cycle Cost Calculator, a quantitative analysis was conducted comparing hot-dip galvanizing to four paint systems, as well as a duplex system and metallizing with defined maintenance schedules.
Initial Cost:
Including materials (paint, metallizing, etc.), the number of coats, the surface prep cleaning method (painted systems: SP-10; duplex: SP-16/ASTM D6386; metallizing: standard near white metal), where the application was performed, and labor costs versus galvanizing’s all-inclusive price:
Coating System
$/ft2
Total
Hot-Dip Galvanizing
$1.76
$ 88,000
Epoxy/Epoxy
$2.92
$ 146,150
Epoxy/Polyurethane
$3.35
$ 167,650
Inorganic Zinc/Epoxy
$3.17
$ 158,650
Inorganic Zinc/Epoxy/Polyurethane
$4.53
$ 226,300
Galvanizing/Epoxy/Polyurethane (Duplex)
$5.28
$ 263,950
Metallizing
$8.37
$ 418,550
These findings indicate that when all the costs are considered, galvanizing is often less expensive and at the very least, exceedingly competitive with other coating systems.
Life Cycle Cost:
Utilizing a practical maintenance cycle over the prescribed 75-year lifetime of the project based on Net Future Value (NFV) and Net Present Value (NPV) calculations at 3% inflation and 2% interest, and accounting for a very unlikely needed maintenance paint with an inorganic zinc at year 70 for the galvanized steel:
Coating System
$/ft2
Total
Hot-Dip Galvanizing
$ 4.29
$ 214,500
Galvanizing/Epoxy/Polyurethane (Duplex)
$22.84
$1,142,000
Inorganic Zinc/Epoxy
$39.92
$1,996,000
Inorganic Zinc/Epoxy/Polyurethane
$41.53
$2,076,500
Epoxy/Epoxy
$51.91
$2,595,500
Epoxy/Polyurethane
$61.63
$3,031,500
Metallizing
$62.80
$3,140,000
Even with the one maintenance cycle near the end of the life of the project, hot-dip galvanizing was proven to have a significantly more economical lifecycle than that of the other coating systems.
Galvanized Steel Protects Your Investment
To maximize return on investment, it’s critical that buyers ensure the longevity of their purchase. Enhanced over 200 years, galvanizing is a process that best protects steel for long-lasting, corrosion-free performance. In fact, galvanized components can potentially last up to a century without the need for costly maintenance, delivering a significantly lower lifecycle cost, especially when compared to alternatives like stainless steel, aluminum, and epoxy coating. And research suggests that non-galvanized structures incur indirect costs as much as 11 times higher than those that utilize galvanized products. In an economy where steel prices are expected only to rise, buyers are wise to protect their investment and achieve cost savings by galvanizing.
GalvXtra Hot-Dip Galvanizing
AZZ’s GalvXtra four-step, hot-dip galvanizing process uses a proprietary formulation of molten metals to deliver consistent, high-quality zinc coatings on ferrous materials. At the preparation stage, steel arrives at AZZ’s galvanizing plant and is inspected to ensure that drainage and venting requirements are met. Then, the metal is cleaned by immersion in a hot alkali solution, acid pickled to remove rust or scale, and fluxed to eliminate surface oxides. Next, the steel is hot-dip galvanized—submerged in a bath of molten zinc to form a shield of zinc/iron intermetallic layers on all surfaces. Finally, the newly galvanized steel is cleaned, weighed, and carefully inspected with calibrated instrumentation to ensure quality standards.
Trust Your Steel to AZZ
AZZ performs hot-dip galvanizing for steel components used in a wide range of applications, including agriculture, bridge & highway, construction, electrical utility, industrial, original equipment manufacturers, petrochemical, recreational, and transportation. Backed by 60 years of experience in the materials industry, AZZ offers exceptional galvanizing service at over 40 locations across the U.S. and Canada. Click to learn more about protecting your steel investment.
Sign up to receive press releases, presentations and additional investor information.
We use cookies on our website to give you the most relevant experience by remembering your preferences and repeat visits. By clicking “Accept”, you consent to the use of ALL the cookies. If essential cookies are disabled, the website may not function properly.
This website uses cookies to improve your experience while you navigate through the website. Out of these, the cookies that are categorized as necessary are stored on your browser as they are essential for the working of basic functionalities of the website. We also use third-party cookies that help us analyze and understand how you use this website. These cookies will be stored in your browser only with your consent. You also have the option to opt-out of these cookies. But opting out of some of these cookies may affect your browsing experience.
Necessary cookies are absolutely essential for the website to function properly. These cookies ensure basic functionalities and security features of the website, anonymously.
Cookie
Duration
Description
cookielawinfo-checkbox-analytics
11 months
This cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Analytics".
cookielawinfo-checkbox-functional
11 months
The cookie is set by GDPR cookie consent to record the user consent for the cookies in the category "Functional".
cookielawinfo-checkbox-necessary
11 months
This cookie is set by GDPR Cookie Consent plugin. The cookies is used to store the user consent for the cookies in the category "Necessary".
cookielawinfo-checkbox-others
11 months
This cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Other.
cookielawinfo-checkbox-performance
11 months
This cookie is set by GDPR Cookie Consent plugin. The cookie is used to store the user consent for the cookies in the category "Performance".
viewed_cookie_policy
11 months
The cookie is set by the GDPR Cookie Consent plugin and is used to store whether or not user has consented to the use of cookies. It does not store any personal data.
Functional cookies help to perform certain functionalities like sharing the content of the website on social media platforms, collect feedbacks, and other third-party features.
Performance cookies are used to understand and analyze the key performance indexes of the website which helps in delivering a better user experience for the visitors.
Analytical cookies are used to understand how visitors interact with the website. These cookies help provide information on metrics the number of visitors, bounce rate, traffic source, etc.
Advertisement cookies are used to provide visitors with relevant ads and marketing campaigns. These cookies track visitors across websites and collect information to provide customized ads.