When it comes to industrial coatings, making the right choice can be a daunting task. Yet each method has its own unique advantages and function. Some options may not be right for you. While there are many different types of industrial coatings to choose from, understanding the costs, savings, benefits, and liabilities associated with each technique is vital in making the right choice.

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While some industrial coatings work well across the board, others are ideal for specialized applications. Start-up costs, maintenance, and the cost of operation should also be taken into consideration to ensure the right choice.

This guide will compare and contrast the many industrial coatings options available to you. Knowing what each option offers will enable you to choose the optimal solution for your unique coatings needs.

Industrial Coatings

There are many different types of industrial coatings, but essentially, the term refers to any coating &#; typically paint &#; used to protect manufactured products from corrosive elements, fire, chemicals, etc. Industrial coatings are the second largest coatings market in the US, worth approximately $7.8 billion USD as of .

Coatings protect and beautify and therefore enhance the value of many items. And the value-added far exceeds the cost of the coating process and materials. Industrial coatings are made from a wide variety of materials, such as alcohols, biobased feedstocks, iron oxide, aluminum pigments, epoxies, polyesters, and even gold.

The Need for Metal Finishing

Metal Finishing has come to refer to protecting both metal and non-metal surfaces, but it has typically referred to the process of applying a finishing coat to protect metal products. It can include both paint and non-paint coatings solutions.

Metals are highly susceptible to rust wherever both oxygen and moisture are present. Pollutants like salts or sulphur dioxide only expedite this degenerative process. Additionally, metal vehicles used by the US military rely on state-of-the-art Chemical Agent Resistant Coatings (CARC) to protect surfaces from chemical and biological warfare agents. Some of the primary reasons for metal finishing include:

• Increased surface thickness
• Aesthetic improvements
• Corrosion resistance
• Increased strength
• Increased adhesion
• Durability
• Improved electrical conductivity
• Chemical resistance
• Enhanced solderability
• Enhanced electrical conductivity

While modern paints have developed greater protective properties than their predecessors, this superior protection is dependent on optimal coating selection, site preparation, and proper application. Undercoats and primers are necessary for some industrial coatings but not others. Baking and heat curing benefit some metal coatings but can damage others. Choosing the proper protective metal coating and metal finishing technique is paramount &#; and it doesn&#;t have to be all that difficult.

Popular Industrial Coatings Methods

There are numerous methods of protecting industrial surfaces currently in use today. Some methods are vastly different than others, while some have subtle pros and cons that should be carefully considered depending on the situation. While most people think of paint when discussing coatings, there are other metal finishing options used in very limited circumstances. In general, the metal coating methods commonly used today include:

• Anodizing
  Most common with aluminum, this method increases the thickness of aluminum oxide that occurs when aluminum is exposed to oxygen. This process makes aluminum (and some other metal surfaces) more resistant to corrosion and can also provide a more adhesive surface for additional coatings.
• Hot Dipping
  Also known as galvanizing, this process involves dipping steel into hot zinc to form a coating of zinc oxide layer. This layer is resistant to rust, and will not flake off due to a metallurgic bond between the substrate and the coating. If later welded, the steel must be painted with a zinc paint to prevent rusting of the joints.
• Electroplating
  This process involves immersing a metal component into a bath containing a dissolved metal &#; typically cadmium, chromium, or nickel &#; and running an electrical current through it. This coats the item with a thin layer of metallic particles. However, uniform thickness is difficult to achieve with this method, and parts subject to abrasion will need to be repeatedly coated.
• Chemical Process
  Chemical coating is sometimes used for paint priming, metal coloring, and corrosion protection. This method involves creating a thin film of sulfide and oxide on a metal surface though chemical reaction.
• Porcelain Enamel
  This process is popular on cast-iron cookware and restroom partitions, as it protects against both scratches and graffiti.
• Painting
  By far the most popular of the different types of industrial coatings, paints can be applied via a handful of popular methods that we will explore further: e-coatings, powder coatings, and liquid coatings. This is where the bulk of industrial coating occurs, and each method offers unique opportunities and challenges.

Liquid Paint

When it comes to paints, liquid is still beneficial in many cases. In spite of advances in coatings technology, liquid paint remains the optimal choice for several situations, such as when:

• The project requires lower cure temperatures
• A process requires faster color changes
• A project requires more color variation
• Products require special masking
• Smoother coats are desired

The most obvious benefit for wet coatings is probably the fact that this method affords so much color variety. Especially useful in specialty markets, the many shades and specialty coatings create far more choices. Indeed, using liquid paint means you have the option for Teflon and even glow-in-the-dark coatings.

Powder Coating

Some situations require the advantages of powder coatings, a technique which involves electrostatically charging the paint pigment powder to cause adhesion to the substrate. This newer technology is rising in demand, and it&#;s easy to see why. In addition to producing a more durable coating more efficiently than liquid, powder coating is generally seen as a more environmentally safe option.

The powder coating process allows for little-to-no waste. Any powder not adhered to the target surface is collected and re-used. Because the paint contains no solvents, virtually no Volatile Organic Compounds (VOCs) are released into the atmosphere as the paint ages.

The technology requires less training than other methods, but the associated operation and energy costs are higher. However, this method allows more control over the film thickness. Additionally, this application is an excellent choice where durability and scratch resistance is important. The method is in high demand for applications such as tire rims and oil pipes.

E-Coating

Electrophoretic deposition &#; also known as e-coating &#; is the process of dipping substrates into a bath of liquid paint that is then electrified to cause adhesion. This is essentially the liquid version of powder coating. And there are several factors to consider when choosing between e-coating and powder coating.

• E-coating allows for highly targeted coating thicknesses, as the amount of electricity applied determines the film thickness.
• E-coating performs quite well in both primer and topcoat applications; cathodic epoxy electrocoat offers superior adhesion and protection as a primer, while cathodic acrylic electrocoat is a superior topcoat technology for protection against UV rays.
• E-coating more easily coats difficult-to-reach areas as a liquid medium and is thus popular in automotive applications.
• Up-front costs are high with this method, but ongoing operation costs are lower than that of other methods.

CARC Coating

Chemical Agent Resistant Coating or CARC coating is a highly useful specialty coating developed for military use in combat zones. The coating is non-porous and therefore non-absorbent and highly resistant to chemical and biological agents. Additionally, it is that much easier to decontaminate &#; especially since CARC coatings are typically more durable.

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CARC coating is also very useful for camouflage. Its unique pigment package confuses infrared technology &#; something not known to previous camo coating technology. This means vehicles using this state-of-the-art coating are nearly invisible to infrared cameras.

Choosing the Right Industrial Coatings

As customer expectations As new lighter materials are introduced into the market, corrosion requirements, evolve, regulations and production requirements evolve, it can be difficult to understand which industrial coatings are right for your situation. Rather than swiftly committing to a coating and increasing speed of process to compensate for any gaps, carefully think through these options. Discuss formulation changes, durability considerations, flexibility, and capability in relation to your desired objectives.

Steel is an incredibly versatile material, with applications in numerous products across many industries, but one factor that gives steel its durability and adaptability is its capacity to be coated by various treatments. Steel surfaces are coated for many reasons, from improving resistance to wear and tear, protection from corrosion and the elements or even just to make them more visually appealing.
 

Steel can be used for just about anything, however, it needs to have the right treatment for the right application. Finding the right coated steel product for your project will drastically increase its performance and longevity.

 
Zinc is the main ingredient used in coating steel as it forms a &#;cathodic protection&#; &#; a method which uses the corrosion of a sacrificial metal (zinc, or zinc alloy), to prevent the base metal (steel) from corroding.

Methods of Coating steel

Zinc and zinc alloys can be applied to steel in a number of ways, however, the most common forms are:

&#; Hot dipping &#; a process of submerging steel in a bath of molten zinc at temperatures of 450°C. After the metal is removed from the bath, the zinc reacts with oxygen and carbon dioxide in the air to form a hardened layer.

&#; Electrogalvanizing &#; a process which uses a current of electricity running through a saline/zinc solution with a zinc anode, as well as a steel conductor.

Types of Coated Steel Products

Different environments and applications require specific steel coatings. Here are some of the most common treatments of steel and their appropriate applications:

Galvanised (GI)

Galvanised steel uses a zinc on steel coating and is generally used for ducting and roofing.
Galvanised steel can be formed using a &#;hot dipping&#; method, as well as electro galvanisation. The metal has a shiny surface finish and a 3 out of 5 rating for corrosion resistance.

Galvannealed (GA)

Galvannealed steel is a zinc on steel coating which is usually used for automobile parts such as outer panels. The metal uses a reaction with Iron and Zinc to form a zinc-iron alloy and is formed with a process of annealing following a hot dipped galvanisation method. Galvannealed steel has a matte finish and scores a 2 out of 5 for corrosion resistance.

Galvalume (GL)

Galvalume steel uses a coating that is 43.5% zinc, 55% aluminium and 1.5% silicon. It is most often used on metal buildings and for roofing applications. It is formed using a continuous hot dipping method and has no surface finish. Galvalume has a high 4 out of 5 corrosion resistance, however, it is a registered and patented trademark brand and only licenced manufacturers can produce the metal.

Galfan (GL)

Galfan steel uses a 95% zinc and 5% aluminium coating and is most often found in white goods and in some automobile parts. It also uses a continuous hot dipping method and does not have a surface finish. It is the most modern product on this list and scores the highest for corrosion resistance, a perfect 5 out of 5. Like Galvalume it is also a patented trademark brand.

Choosing the right treatment

It is important to choose the right steel coated product to suit the needs of the application. Aesthetic factors may need to be considered, as well as corrosion concerns, such as humidity, temperature, salinity and whether the metal will be indoors or outdoors.

Steel is strong, durable and incredibly versatile, however, if it does not have the appropriate surface treatment, its quality will be quickly undermined, be sure to contact an expert for the best coated steel product for your project.

If you need coated steel products to suit your unique needs, contact Steel Fabrication Services today.