All about powder coating

Are you looking for alternatives to paint for your steel fabrications? You may have heard about powder coating, but not be sure what it is or what it involves. In this blog, we cover everything there is to know about powder coating and how it is superior to traditional liquid paint.

What is powder coating?

Powder coating is a longer lasting coating alternative to traditional liquid paint. Instead of being applied in liquid form with a paintbrush or roller, it is applied in a powder format with an electrostatic spray gun.

The gun charges the powder particles with electrostatic charge, helping the particles to adhere to the metal surface. This process means that the finish achieved is much more durable and corrosion-resistant than traditional paint. Although frequently done on steel fabrications, it is also possible to powder coat aluminium.

When applied in combination with hot dip galvanizing, it helps protect steel against corrosion for multiple decades.

Can you powder coat aluminium?

Yes. Like steel, aluminium can be powder coated. However, unlike steel, aluminium cannot be hot dip galvanized.

How is powder coating performed?

Before coating, the steel’s surface must be thoroughly cleaned to remove any dirt, grease, or rust. The powder coating is then sprayed on using an electrostatic spray gun in the fabricator’s or specifier’s colour of choice. The powder itself is made up of finely ground particles of pigment and resin.

After application, the coated item is heated in an oven at high temperatures, typically between 175-200°C. The heat causes the powder to melt and flow, creating a smooth, even coating. The coating then solidifies and chemically reacts to form a hard, durable finish. This curing process provides low maintenance and long lasting corrosion protection for steel.

Why powder coating is better than paint

Powder coating offers several benefits over traditional paint.

Improved durability and corrosion resistance

Powder coating is more durable than traditional paint. It is resistant to chipping, scratching, and fading, leaving the fabrication looking nicer for longer. It also makes it cheaper over its lifetime due to a reduced need to maintain the coating.

Powder coating is also much more resistant to corrosion compared to liquid paint. This helps the underlying steel to last longer, too, reducing the need for complete refabrication.

Quicker drying time

Paint needs several days to dry after it has been applied. It also needs multiple coats to achieve the desired result. In contrast, a powder coat can be completed in one sitting and has a quicker drying time. This means you get your fabrication back quicker and spend less time waiting – ideal if you have a tight deadline you need to work towards.

Environmentally friendly

Powder coating is an environmentally friendly alternative to traditional paint. It produces less waste, and the powder can be recycled. Additionally, paint contains toxic solvents that damage the environment. The powder coating solution does not contain toxic solvents and is safer for operators to apply, provided the correct PPE is used for the job.

Lower lifetime costs

Powder coating is a cost-effective alternative to traditional paint, thanks to its increased durability and recyclability. The time and money that would otherwise be spent re-painting the steel on a regular basis is reduced, because the powder coating layer is much more durable.

What colours can I powder coat my steel?

If you can think of a colour, it is almost certainly available in powder coating. Powder coating paints come in many different colours, and can be used to create different finishes such as textured or metallic.

Anodic

Anodic is a range of exclusive metallic effect powder coating finishes – providing a great alternative to anodized aluminium. This range is supplied in Interpon D2525 ultra-durable polyester technology.

Futura

Futura is a range of special powder coating finishes for use on exterior architectural metal components.

Structura

Structura is a range of special powder coating finishes for use on exterior architectural metal components.

Brilliance

Brilliance is a range of revolutionary single-coat powder application that achieves a finish previously only realised using liquid coatings. The Brilliance finishes are available in different durability levels, which provide excellent interior and exterior durability.

Traditional RAL colours

We can produce any specified traditional RAL colour for any type or size of project, be it for raw steel substrate in an interior or a galvanized substrate for an exterior.

Powder coating at Joseph Ash Galvanizing

Our dedicated powder coating facility at Joseph Ash Medway is the ideal location for powder coating your steel. Based in Kent, our site offers a collection and delivery service to the surrounding area, and offers a one-stop-shot of hot dip galvanizing, steel and aluminium powder coating, and shot blasting.

We can produce any specified colour or texture for any size or type of project you have, whether it’s a raw steel substrate in an interior or a galvanized substrate for an exterior.

Joseph Ash Medway is among only a handful of companies to be an approved AkzoNobel paint applicator, and is the only one to be based in the South East.

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Steel protection services such as galvanizing have become modernised to fit into a sustainable future. However, are alternative coating technologies such as powder coating as sustainable? We explore what powder coating is, whether it fits into a sustainable future, and how it compares to traditional coating methods such as paint.

What is powder coating?

Powder coating is a steel coating method where coloured powder is electrostatically sprayed onto the surface of the metal. It is used as an alternative to paint, boasting many benefits where paint may fall short. As the powder is cured into the steel, it gives an extra layer of protection against corrosion and avoids chipping and damage. It can be used on top of galvanized steel to extends its lifespan even further.

Is powder coating sustainable?

Powder coating is more sustainable and environmentally friendly than paint in many ways.

Reduced VOC emissions

Traditional liquid paints often contain volatile organic compounds (VOCs), which can contribute to air pollution and have potential health hazards. Powder coating, on the other hand, releases negligible amounts of VOCs into the atmosphere during the application process.

Reduced waste

The increased lifespan for steel also means that there is less need to fabricate new structures, reducing any environmental impact associated with steel fabrication. This helps powder coating form part of a circular economy.

Waste disposal

The already-minimal waste generated from the powder coating process is often less hazardous than waste from traditional paint processes. Disposal of unused powder coating material is generally easier and less environmentally impactful than the disposal of leftover liquid paint and associated solvents.

This, in combination with powder coating’s material efficiency, means that powder coating is a very sustainable choice.

All companies are responsible for sustainability

Although powder coating is more sustainable than paint, it’s important to note that the overall sustainability of a product also depends on factors such as the raw material sourcing, manufacturing processes, and end-of-life considerations.

The steel protection industry is still heavily reliant on transportation between plants and clients, impacting the environment. Fortunately, solutions are being implemented to minimise this, such as using hydrogenated vegetable oil in fleet vehicles, and making all forklifts electric. Company cars at Joseph Ash Galvanizing have made the shift to electric, too. Lastly, electricity comes from renewable sources, both on-site (from solar PV arrays) and externally (by using a renewable tariff with our supplier).

All companies – regardless of industry – also need to ensure they work with companies that share their sustainability goals. At Joseph Ash Galvanizing, all suppliers are vetted to include environmental accreditations and carbon reduction plans. We, in turn, are accredited to Environmental Management ISO14001 Standards.

Sustainable powder coating at Joseph Ash Galvanizing

Joseph Ash Medway is our one-stop shop facility for shot blasting, galvanizing, and powder coating.

• Protect steel against corrosion
• Collection and delivery service
• Fast turnaround times
• AkzoNobel approved supplier of powder coating
• A wide range of powder coating colours and finishes

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Powder coating is a popular alternative to paint that serves many benefits that paint cannot. While the two coating methods may seem similar, powder coating has numerous benefits compared to paint. We cover what powder coating is and what benefits it brings. We will also explore why powder coating is better than paint, and its relevance for various industries.

What is powder coating?

Powder coating is a process that involves applying a dry powder to a metal surface. The powder is sprayed on the surface with a spray gun, and the fabrication is then cured in an oven under a high temperature to form a tough, durable skin. It can be applied over galvanized metal to make it even more durable.

Like paint, powder coating is used for protecting the material underneath, and enhancing the steel’s visual appeal with a wide range of possible textures and colours. However, powder coating is superior to paint as it is cheaper, quicker, more durable, and more environmentally friendly.

Benefits of powder coating

Powder coating offers several benefits over traditional paint, including:

Durability: Powder coating is more durable than traditional paint. It is resistant to chipping, scratching, and fading, leaving the fabrication looking nicer for longer. Because powder coating reduces how often the steel needs to be treated, maintenance becomes cheaper overall.

Time-saving: Paint needs several days to dry after it has been applied. It also needs multiple coats to achieve the desired result. In contrast, a powder coat can be completed in one sitting and has a quicker drying time. This means you get your fabrication back quicker and spend less time waiting.

Environmentally friendly: Powder coating is an environmentally friendly alternative to traditional paint. It produces less waste, and the powder can be recycled. Additionally, paint contains toxic solvents that damage the environment. The powder coating solution does not contain toxic solvents and is safer for operators to apply, provided the correct PPE is used for the job.

Versatility: There’s no need to compromise on aesthetic appeal when you opt for powder coating. Available in many colours and textures, there’s plenty of choice on colour and finish, including metallic, glossy, and matte. This versatility allows for greater customization and design options.

Cost-effective: Powder coating is a cost-effective alternative to traditional paint, thanks to its increased durability and recyclability. The reduced costs come from the reduced need to re-coat your steel or aluminium.

Powder coating for steel

Powder coating is beneficial for steel in a wide range of industries. The automotive industry can benefit from powder coating as it can coat everything from cars and trucks, to motorcycle parts and trailers. It can also be used in the aerospace and marine industries to coat aircraft parts and marine equipment.

The construction industry can coat structural steel, fencing, gates, and other building components. Similarly, it is also used in the architectural industry to coat window frames and doors. Powder coating is most beneficial for industries that require a durable, long-lasting coating that can withstand harsh environments. It is ideal for increasing the visual impact of your metal and helping it stand out. You can view our photo gallery if you’d like to see some examples.

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Our dedicated facility in Sittingbourne, Kent, is AkzoNobel approved, and skilled in using a wide range of powder coating paints from many other suppliers.

Contact us today for a quote or to book a collection.

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Galvanizing and powder coating can be used together

Hot dip galvanizing and powder coating are the most popular and well-known methods of steel protection. People often consider using only one type of coating, based on the desired outcome for the steel fabrication. But what happens when two methods of coating are used at the same time? A duplex coating is achieved.

The term ‘duplex coating’ covers any type of coating that uses two methods together. However, at Joseph Ash Galvanizing, we use this term for the combination of hot dip galvanizing and powder coating – a powerful synergy, suitable for all types of steel fabrication.

Benefits of duplex coatings

1. Increased durability

When used independently, hot dip galvanizing creates an incredibly durable finish. However, as steel ages, the galvanized zinc coating will eventually erode, making the steel more susceptible to atmospheric attack. Therefore, covering it with an extra layer increases the lifespan even further. The extra coat provides an additional barrier, slowing down the erosion rate and providing a superior level of protection.

2. Environmentally friendly

Hot dip galvanizing and powder coating have minimal impact on the environment. Our plants our self-contained, with steel going in at one end and the final product coming out at the other. This allows us to control and reuse the waste products emitted, minimising the amount released into the environment.

The galvanizing process never uses more zinc than the steelwork needs to coat it due to the metal’s non-ferrous properties, reducing material waste. Both powder coating and zinc coatings allow the steel to be recycled without loss of properties, contributing towards the principles of a circular economy.

3. Cost effective

The cost of duplex coatings is low compared to other metal protection methods. Thanks to its high durability, duplex coated steelwork needs treatment less frequently, resulting in long-term money savings.

Many galvanizing plants do not offer both hot dip galvanizing and powder coating. Joseph Ash Medway, however, is a one-stop-shop service provider for hot dip galvanizing, powder coating, duplex coatings and shot blasting, providing all services under one roof. This drastically reduces the costs associated with transportation and having to use two suppliers.

4. A wide range of colours

While galvanizing will leave your steel with a shiny silver finish, powder coatings come in various colours. This can be desirable and impactful depending on what you are having coated; imagine a bright and vibrant fence or gate, or fully coloured sculpture placed in the middle of a busy city. There are plenty of photos in our gallery for inspiration. If you can think of a colour, we can produce it! You can also choose to have a textured finish with varying matt, satin, and gloss levels.

5. Quality assured

Although galvanizing and powder coating have a traditionally long lifespan, not all steel coating service providers are equal. All steelwork treated at Joseph Ash plants adheres to the coating’s requirements of BS EN ISO 1461 and BS EN ISO 9000 quality assurance specifications. You can rest assured knowing that we hold numerous accreditations from various organisations.

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Our Medway plant offers a 40-year guarantee on duplex coatings (subject to T&Cs). If you’re interested in Joseph Ash Medway’s specialty duplex coatings, get in touch today to discuss your requirements.

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