Powder coating is arguably the superior way to finish structural steel frames than paint, for use in the construction industry. Before powder coating, you’ll need to prepare the surfaces by sandblasting. Melbourne powder coating businesses with years of experience will give you several reasons to sandblast and powder coat structural steel.
What is powder coating?
Powder coating medium is a finely ground blend of pigment and resin that can create a protective finish. Modern industrial metal equipment is rarely painted anymore. Instead, they are first sandblasted in preparation for a surface coating. Then the metal is powder-coated in a dry process.
A dry powder is applied to the metal through an electrostatic process. The powder is charged with static electricity. Then it is sprayed onto the electrically grounded steel. The surface is finally cured with heat and the powder melts in a uniform film.
The difference between powder coating and paint is that paint contains a solvent. The differences in chemical composition between paint and powder coating are responsible for the differences in performance. In both cases, surfaces need to be prepared with media blasting.
Types of powder coating
Two types of powder coating are used in the industry:
- Thermoplastic powder coating – the finish becomes soft and liquid when heated. In other words, no chemical bonds are formed. The coating can thus be reused and the process reversed when removing the finish.
- Thermoset powder coating – these are thicker finishes and more durable than thermoplastic coatings, due to chemical bonds. They are recommended for automobiles, refrigerators and steel frames for the heavy-duty construction industry.
In the construction industry, powder coating is often seen on door and window frames, guardrails, modular furniture, lampposts, fencing etc. Powder coating steel frames rather than liquid painting them for surface treatment is better for several reasons.
Benefits of powder coating structural steel
- Strength, flexibility and durability
Powder coating surface finishes are highly durable, far more so than paint. When the powder is cured and melts, it forms long chemical bonds for a strong, hard finish. The powder coating is also more flexible than traditional paint. Durable steel frames are made more durable with powder coating, and they can withstand damage better.
Powder coating dries thick and chemically bonded. Where necessary, thicker layers can be applied. Note that powder coating is not entirely invulnerable. Long term exposure to the elements can lead to chalking. In chalking, sunlight, heat and moisture break down resins and loosen some particles of pigment and resin, leading to a slight fading. But with polyester-based coatings as topcoats, the resilience of the coating can be improved. Overall, powder coating leads to better colour retention than paint.
- Quick, easy and cost-effective process
The powder coating process is fast. An electrostatic gun shoots dry powder onto the metal surface. The gun negatively charges the powder, which is attracted to the electrically grounded surface. Using the powers of magnetic attraction, the process becomes much faster. When the coating reaches the thickness desired, the surface can be cured for a smooth finish.
The process is also cost-effective. Besides the monetary value of the time saved in a faster process, powder coating is cost-effective in other ways. You can purchase raw materials only as required. The powder tends to be less expensive than paint, and it is easier to store than paint cans. Labour costs also tend to be on the lower side.
Overall, the upfront costs of powder coating can be higher than wet paint. But in the long run, it turns out to be cheaper. The upfront costs lie in the equipment, some of which is passed on to customers. But the savings add up quickly. Costs of insurance and mitigation measures associated with paint don’t apply to powder coating.
- Uniform application and great coverage
Because of the nature of the process, powder coating is applied evenly across large surfaces. On the other hand, paint needs to be applied by trained experts or a spray-painter with a steady hand. Steel frames need to be protected against the weather, and powder coating turns out to be more durable and cost-effective than paint. Because it is quick to apply, you can cover larger surfaces with it.
- Corrosion & chip resistance
Structural steel frames are usually treated with hot zinc coating or powder coating to protect against corrosive moisture and humidity.
The protective barrier formed by powder coating is also chip resistant. Paint is liable to crack with time and weathering. It can chip, scratch and peel easily, which is not the case with powder-coated finishes. Powder-coated structural steel frames can hold up better to the environment. This is due to the chemical bonding that takes place on the surface during curing. It can also be applied in thicker, more durable layers in outdoor applications.
- No maintenance
Powder-coated structural steel is extremely low maintenance. Steel, to begin with, is a durable, cost-effective and versatile building material. Repairs to steel, replacements and maintenance fees are minimal across decades. Powder coating structural steel further enhances its sturdiness and durability, making it a highly low maintenance material.
Several construction businesses in the South Eastern Suburbs of Melbourne rely on powder-coated steel frames for their development projects. You don’t need any special solvents to clean structural steel that’s been powder coated. Where necessary, it just needs to be wiped down with soapy water and rinsed.
- Longevity of finish and colours
Not only is the finish hard and tougher than traditional paint, but it also stays brighter for longer. You’re able to customize colours and finishes as you need. Manufacturers will be able to customize powder blends for your particular needs. You can also achieve different textures where you need them.
- Environmentally safe
Powder coating is relatively safe for the environment than paint and other options. The powder doesn’t contain any solvents that could create toxic fumes and pollute the work environment. Less waste is released through spraying powder coating. Of course, spray painters will still need to wear protective gear to not inhale the powder. They also wear goggles and prevent skin contact with the powders.
The Bottomline
Powder coating on structural steel frames outperforms liquid paint. As long as you have the right equipment for the application, you can cut down on the processing time, improve the surface finish quality and strengthen the foundations of the construction project. Using powder coating will help you store and dispose of materials easier and in a more environment-friendly way.
At Doogood Surface Coating and powder coating in Melbourne, we powder coat steel frames for commercial projects, development sites, housing developments, apartments etc. We number among the abrasive blasting contractors in Melbourne who provide the full service from surface preparation to powder coating finishes.
Our services range from bolt coatings and fastener coatings all the way to larger projects such as surface finishing structural steel frames. Get in touch to find out how we can help you achieve quality in your developmental project. When it comes to abrasive blasting, Melbourne contractors turn to us for quality work.
Health & Safety
At Doogood Surface and Powder Coating in Melbourne, we strictly follow Australian Council rules and regulations for safety. Powder coating is safer to apply and store than paint, which makes our job often easier. It is not flammable like liquid paint. It also doesn’t release VOCs (volatile organic compounds) that could harm our operators. For our abrasive blasting services, spray painting services and others, we strictly follow safety rules.
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