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.
Project Spotlight: Navajo Lake Marina Expansion (AZZ Galvanizing – Chelsea)
Navajo Lake State Park, just a short 40 miles east of Farmington, New Mexico, is the ultimate playground for adventurers. With 150 miles of shoreline, New Mexico’s second largest lake is the perfect getaway for boating, sailing and fishing enthusiasts.
Designed, manufactured and installed by Marine Development Inc (MDI), the newly expanded Navajo Lake Marina now includes more than 600 slips with over 100 mooring balls for rent. Metal structures located in or near bodies of water are some of the most challenging applications to protect from corrosion. Water hardness/softness, temperature, impurities, ph and movement of the water all play a role in the aggressiveness of corrosion.
The principles for MDI have been building boat docks, slips, marinas and other water structures for over half a century. As far back as the 1960’s, the most effective protection from corrosion for these water applications has been hot-dip galvanizing (HDG). Some of MDI’s earliest galvanized structures are still in use today, a reoccurring testimonial to the cost effectiveness of HDG.
HDG is the process of metallurgically bonding zinc to steel. Properly prepared steel is dipped in a kettle of molten zinc where zinc and iron alloy layers form over the steel surface. Once the coating is complete and the steel has cooled, the thin, durable, well adhered zinc coating is ready to take on a myriad of corrosive applications.
The galvanic series lists metals by their electrochemical activity in seawater. Metals higher on the list are sacrificial to the metals that are lower on the list when electrically connected. Zinc is higher on the galvanic list than steel, so zinc will provide sacrificial protection to the steel when the two are connected and exposed to an electrolyte (water/moisture). The zinc coating slowly sacrifices itself over time while providing decades of maintenance free protection in countless water applications.
You won’t hear many complaints from environmentalists regarding the use of HDG coatings in or near water as there is no harm to our most essential resource and no impact on aquatic life. Zinc already exists in the water as well as within every living creature. MDI will continue building these attractive, floating, recreational facilities and hot-dip galvanizing will continue to provide that small, but vital role.
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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