The coil coating process

The metal substrate (steel or aluminium) is delivered in coil form from the rolling mills. Coils weight varies from 5-6 tonnes for Aluminium and up to 20 tonnes for steel.

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The coil is positioned at the beginning of the line, and then unwound at a constant speed, passing through the various pre-treatment and coating processes before being recoiled.

Two strip accumulators found at the beginning and the end of the line enable the work to be continuous, allowing new coils to be added (and finished coils removed) by a metal stitching process without having to slow down or stop the line.

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The following steps take place on a modern coating line:

• Mechanical stitching of the strip to its predecessor
• Cleaning the strip
• Power brushing
• Surface treatment by chemical conversion
• Drying the strip
• Application of primer on one or both sides
• Passage through the first curing oven (between 15 to 60 seconds)
• Cooling down the strip
• Coating the finish on one or both sides
• Passage through the second curing oven (between 15 to 60 seconds)
• Cooling down to room temperature
• Rewinding of the coated coil.

Coil stock finds its utility in crafting items such as gutters and flashings, typically on-site. Skilled tradesmen can tailor-make various components from it, the paint used remains flexible even when the material is bent or shaped. On the contrary, powder coating tends to crack under such manipulation. Powder coating, although offering superior quality, comes at a higher cost, and aligns with the premium quality of aluminum extrusion. In contrast, the more economical thin gauge coil is a better match for wet paint, which is generally cheaper.

While both powder coated aluminum and coil coated aluminum offer exceptional durability and corrosion resistance, their suitability in specific applications varies. Factors such as budget, design requirements, and environmental conditions can play a part in the decision-making process. Understanding the unique properties and advantages of each material is essential for making informed decisions and achieving optimal results in construction, manufacturing, and design projects. Whether you opt for the versatility of powder coated aluminum or the robustness of the coil coat process both materials can deliver superior performance.

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