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.
In 3½ years, 450 north St. Louis County and St. Louis city men have been part of a transformative program called Save Our Sons (“SOS”). The program, designed to prepare African-American men for jobs, especially those who are not getting a foot in the door based on their criminal background, lack of education, work experience or color of their skin held a graduation ceremony for their 29th SOS class on August 3, 2018. Among the men recognized at the ceremony was AZZ Assistant Supervisor Harold Lee.
“This program opened my eyes to a better way out”, said Lee. “I am turning 30 soon enough. I don’t want that life for my kids”. Lee was raised in a single family home and was introduced to the gang lifestyle, by family members, at the young age of 8. He’s been in and out of the prison system and is thankful for the opportunity to turn his life around.
Lee’s journey exemplifies the AZZ Mission Statement, which is ‘to create superior value in a culture where people can grow and TRAITS matter’. TRAITS is an acronym for the values of Trust, Respect, Accountability, Integrity, Teamwork and Safety. Accountability, in particular, is defined as ‘taking responsibility for our actions, and ownership of results. We do what we commit to, both personally and as a team’.
Congratulations to Harold Lee and his personal accomplishment!
A popular coating for industrial components, powder coating is the electrostatic application of a dry powder to a surface which is then cured to form a protective layer that prevents destructive materials from penetrating and reaching the surface. It also provides maximum protection against chipping and scratching that can last many years even in harsh conditions. Further, it is available in countless color options to complement any customer application.
While also offering an extra layer of protection to surfaces, galvanizing is instead achieved by adding a layer of zinc coating through a hot dipping process, providing a tough armor to safeguard against rust and corrosion. Galvanized surfaces are thicker and require less maintenance. In addition, galvanizing can be applied quickly, typically costs less than powder coating, and can protect steel surfaces for 50 years or more.
AZZ has been delivering leading corrosion protection to the steel fabrication industry for more than 40 years, ensuring structural assets are corrosion free, safe, and sustainable. Proud to serve the Aerospace and Defense sectors, AZZ maintains certifications in various processes, including ISO 9001, AS9100, and Nadcap. With two strategically located powder coating locations in Texas, AZZ can process items up to 60’ long and can handle parts weighing up to 60,000 lbs.
Watch this video to see Technical Director Tony Pajoohi and General Manager Ed Garza explain how AZZ is creating a stronger, safer world.
Like the rest of America’s infrastructure, this system is aging, with half of the existing pipeline now more than half a century old. That means it’s more important than ever to use the latest technology available to keep the existing system running safely and efficiently.
Safe pipelines begin with stringent construction regulations. Every pipeline installed today is tested by filling it with water and pressurizing it well above its operating pressure. Today’s pipelines also use advanced materials and anti-corrosion coatings to help prevent leaks. In addition, new super lightweight polymer aerogels are being used to improve the compression resistance of steel pipe and reduce pipe corrosion caused by friction. Graphene-infused polymers show promise as well, improving strength, toughness, permeation resistance, and fatigue performance.
Most pipelines are continuously managed and monitored using information supplied by sophisticated instruments positioned along the length of the pipeline. Control room operators look for changes in line pressure and flow rate which might indicate a rupture. They can then quickly turn off pumps and close shutoff valves to avoid potential spills. Pipelines are also monitored by foot and aerial patrols, and by members of the local community.
Pipelines are regularly inspected to identify potential issues and address them before they become major problems. The primary method is in-line inspection, in which high-tech diagnostic devices called “smart pigs” use magnetic resonance or ultrasonic waves to identify dents, corrosion, or cracking. Specialized software is then employed to analyze the results, identify potential issues, and schedule maintenance. With the use of smart pigs, corrosion-related pipeline incidents have been reduced by 76% since 1999. And new intelligent machines are currently being tested that take this one step further by detecting leaks and then injecting sealants to repair them on the spot. This eliminates the cost and downtime of excavating in order to perform repairs.
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