Unlocking The Benefits Of Powder Coating Finishes

Imagine a world where your car’s paint job lasts longer, your patio furniture doesn’t chip, and your appliances maintain their sleek appearance for years. That’s the world of powder coating - a game-changing technology that has revolutionized the coating industry. In this blog post, we’ll dive into the fascinating world of powder coating, exploring its components, processes, and advantages over conventional liquid coatings. Get ready to unlock the benefits of this durable, cost-effective, and eco-friendly finishing solution.

Key Takeaways

Powder coating technology is a dry finishing technique that offers uniform finishes, enhanced durability and diverse colors.

It utilizes an electrostatic process for even coverage and has two primary materials: thermoset & thermoplastic.

When it comes to protecting surfaces against corrosion and enhancing durability, fusion bonded epoxy (FBE) coating has emerged as a popular choice in the city of Houston. Fusion bonded epoxy is a thermosetting powder coating that is commonly used as a protective coating for steel and other metal objects. It is applied to the surface of the material in a powder form and then heated, causing the powder to melt and fuse with the metal substrate, creating a strong and corrosion-resistant barrier.

Applications of Fusion Bonded Epoxy

The versatility of fusion bonded epoxy makes it suitable for a wide range of applications in Houston. Here are some of the key uses of FBE coating:

Powder coating is well known for its durability, attractiveness, and unmatched corrosion and environmental protection.  What it is less known for, but perhaps its greatest asset, is its eco-friendliness. Powder coating in Houston boasts many environmental impact advantages when compared with other types of coating processes.

No Volatile Organic Compounds

Volatile organic compounds (VOC for short) are chemicals found in the air from a variety of industries. These can include but are not limited to liquid paint and paint strippers, adhesives, cleaners, pesticides, air fresheners, and gasoline fumes. Powder coating and liquid paint coating industries are closely related but vastly different when it comes to environmental impact. All coatings need time to cure to reach maximum durability. Liquid coatings release VOCs as they cure and also as they are applied. While some liquid paints are classified as low-VOC, they still emit hazardous fumes as they are applied and as they cure over time. Choosing powder coating over liquid coating means not only will you get a more durable, attractive finish, but you can rest easy knowing your order won’t contribute to air pollution. 

Architectural powder coating in Houston covers surfaces from railings, metal facades, window and door frames, vents, soffit and fascia, fences, and more. In a climate like Houston’s, having the ultimate protection against the environment with powder coating saves money on costly renovations due to corrosion or peeling paint. High-rises are relatively new to powder coating, with one of the first high rises to use powder coating being built in New York City in 2020. The 51-story Hudson Yards structure took over twenty thousand pounds of PPG’s Coraflon powder coating to the metal elements for the exterior of the building. The company responsible for the massive undertaking used FEVE, or fluoroethylene vinyl ether, which unlike other architectural powder coatings can be applied at ambient temperature rather than requiring high temperatures to cure. FEVE provides excellent color retention, which for a high-rise is important, as well as high-degradation resistance to air pollution and environmental effects. 

Architects and contractors have been using powder coating shops in Houston for decades for their structure needs because the protection and durability is unmatched when compared to liquid coatings. Stair and balcony rails, decorative metal facades, vents, etc. all can be powder coated for optimum protection of surfaces. Powder coating surfaces for large buildings and commercial buildings is optimal, as the longevity and durability of the coatings makes it a cost-effective option. For high-rises specifically, keeping the exterior looking new for as long as possible is desirable because of the impracticality of frequent touch-ups and repairs.

Powder coating in Houston is more than just spraying the coating, curing, and handing off to the client. Proper preparation methods as well as making sure powders are not contaminated ensure that the client gets the most life out of the coating and that the coating looks flawless if it is on a visible surface. 

When it comes to corrosion resistance, industrial powder coatings in Houston are known for their high level of durability. Corrosive environments are more than industrial zones that handle chemicals both liquid and airborne, with the outdoors being the main corrosive environment powder coated machinery and products are exposed to. In Houston, the outdoors subjects machinery, buildings, vehicles, park equipment, etc. to high heat, high humidity, and in some areas higher levels of general pollution because of its vast number of industrial plants. 

Also, because of Houston’s relative proximity to the coast of the Gulf of Mexico, there is a higher level of sea salt in the air that also can be highly corrosive to metals not protected by powder coatings. To determine if a coating gives maximum durability to the object it is protecting in an area, real-world testing in the location of the powder coating shop/client’s area is a good idea. While this isn’t practical for everything, many powder coating manufacturers should be able to inform powder coating shops in Houston what the best coating systems are for different needs.

The biggest difference between thermoset powder coatings and thermoplastic powder coatings is how they react under high temperatures. Thermoplastic coatings will melt and turn liquid again under high heat because they do not chemically react with the surface they adhere to. Thermoset coatings will not melt under high temperatures and are therefore used in industries where the powder coated object will be subjected to harsh conditions. The science behind thermoset powder coatings in Houston is a chemical process called cross-linking during the heat curing process. After it has cooled and set, the thermoset powder maintains its hardness when heat is reintroduced. 

Polyester Thermoset Powder

This type of thermoset powder is the most commonly used powder coating in Houston. Over 60 percent of the market uses polyester-based powder coatings because of its durability and ability to withstand constant outdoor exposure.

Powder coating is a great option to coat metals like aluminum and protect them from a harsh environment. The powder coating method ensures a durable, long-lasting finish that is environmentally friendly and cost-effective. However, to get the durability you expect out of powder coated aluminum, pre-treatments are necessary to make an optimum surface for the powder coating to stick to.

The first step in pre-treatment of aluminum for powder coating is degreasing. The method of degreasing for the aluminum will depend entirely on the surface of the metal and the pollutants involved. The three primary methods of degreasing aluminum for powder coating are solvent cleaning, vapor cleaning, and emulsion cleaning. Solvent cleaning is the best method if you need to preserve the surface of the metal. Heavy grease and oil are removed from the surface using a solvent-soaked cloth and wiping the surface clean. Emulsion cleaning and alkali cleaning use a solvent with a higher pH and a dipping method. The metal is dipped in the solvent for a few minutes, removed, and rinsed.

Removing rust is the second pre-treatment step for powder coating aluminum in Houston. Corrosion is a major weakness for metal, and the whole reason behind powder coating is to prevent corrosion. However, that doesn’t mean a surface is ruined if rust is present. It can be removed and then powder coated to further protect the metal from further corrosion. Rust is easily dissolved with acid, so this pre-treatment step is relatively simple. This method will also require a rinse afterward.

Professional painters and industrial powder coaters in Houston will tell you that a job is only as good as the prep work.  Poor prep work?  Poor job. While often referred to as sandblasting, that is a misnomer as many types of media are available to be used and sand is not typically one of them.  The specifics of the job, and the type of stripping you need to do, will determine what kind of media you use. 

Aluminum oxide is the most frequently used media form for prep work before industrial powder coatings. Its hardness and strength make it the perfect media to prepare surfaces for powder coating where the removal of rust or previous coatings is necessary.  Aluminum oxide works best with harder metals like titanium and stainless steel but can work with softer metals if enough care and attention is given. It is great at removing old powder coating as well. It can be reused, and as it is expensive, using it in a media blasting cabinet where it can be recovered is typical practice.

Industrial powder coating works best with a well-prepped surface. Foreign contaminants such as dirt, oils, old paint, etc. can create an imperfect finish.  Imperfect finishes are not as durable and do not look as nice. While not completely necessary and technically optional, media blasting before coating is considered an essential step by many professional industrial powder coating shops in Houston. 

Powder coating in Houston is a vast industry with a plethora of uses. Outdoor furniture, architectural use, industrial use, municipal and infrastructure possibilities, etc. all benefit from powder coating in one way or another. Powder coating is a dry powder made from a mix of curatives, flow modifiers, and leveling agents. The powder is applied with a sprayer to electrostatically charged surfaces and then cured in an oven. Thermoplastic powder coatings fuse to the surface using heat and can melt after the curing process if reintroduced to excess heat. Thermoset powder coatings become set in their physical and chemical properties after their initial curing process, making them more durable and appropriate for use in industrial settings where exposure to high heat and chemicals is likely. 

When you make an appointment with Houston Powder Coaters to discuss your powder coating needs, you will quickly find out that because of HPC’s size and high output, they have a great relationship with many powder coating suppliers. They can quickly get you what you need if they do not have it in stock. They also work with powder coating suppliers to provide custom, specialty colors to clients who require specific colors for their products due to HOA restrictions, safety restrictions, or simple logo matching, etc. HPC’s special order colors are any color that exists on the RAL color chart for powder coatings and are considered non-inventory. These are not custom colors, but rather colors not frequently used, so they are not kept in stock. Custom colors can be formulated to match exact shades and specifications when provided with a swatch.  Whether you want to match your new powder coating to an existing coating or match it to your company logo, Houston Powder Coaters can get it done.

Fusion bonded epoxy in Houston is a type of powder coating that is classified as a protective coating. It is applied by applying the coating to an already cleaned and preheated to over 400 degrees Fahrenheit surface. As the epoxy powder is applied, it melts and fuses to the surface, creating a protective barrier. Because fusion bonded epoxy (FBE for short) is a thermoset coating, it cannot go back to its original form and further heating of the FBE coated surface will not allow the FBE to melt. This is great for industries where FBE is needed to protect the surface from corrosive materials and elements such as water, chemicals, heat, UV rays, and more.  FBE is different from other powder coatings in that it is used mainly in industries such as the oil and gas industry and the space industry.  In oil and gas, FBE in Houston is used to coat the interior and exterior of pipelines to ensure maximum protection from the corrosive materials the pipeline is exposed to. 

While traditional powder coating can be used for a myriad of things, FBE is best suited to heavy industry, as it is not necessary or suitable for everything.  Depending on the usage of what you need powder coated, traditional powder coating methods can do their job efficiently.  Unlike FBE, traditional powder coating relies on spraying the powder onto an electrostatically-charged surface, then baking the powder onto the surface in large batch ovens.  Metal patio furniture, public space items such as park benches, bike racks, etc, as well as the appliance industry all benefit from traditional powder coating in Houston.

Architecture/Building Powder Coating

The architecture and building industries use powder coating in many different ways. When it comes commercial buildings, whether they be skyscrapers, smaller buildings, or large warehouses, many aspects of the structure can benefit from powder coating in Houston. Door and window facades benefit from powder coating because of their constant exposure to the elements. Other architectural elements that can be powder coated are metal facades, stair railings, metal fencing, soffit and fascia, light poles, and more. 

Oil & Gas Industry Powder Coating

The oil and gas industry uses powder coating in Houston for all kinds of things. Most notable is powder coating the interior and exterior of pipes for pipelines to protect the integrity of the materials. Oil and gas pipelines can carry corrosive chemicals, so they require great protection against corrosive and abrasive elements, and fusion bonded epoxy coatings in Houston do just that. The powder coating industry in Houston also works with oil and gas companies to protect certain elements of their refineries, storage tanks, and field equipment.

Powder coating has taken over global industries because of its versatility, environmental friendliness, durability, and more. Not a day goes by where you do not see at least one item that has a powder-coated element. That bright red tool chest in your garage? Powder coated. The transformers on your neighborhood power lines? Powder coated. Exercise equipment, mailboxes, sports equipment, park play areas? Powder coated. They all benefit from the durability of powder coating in Houston.

There are many industries across the world that benefit from powder coating.  The architecture/building industry, oil and gas industry, appliance and automotive industries, etc., all make use of powder coating for their products and services in one way or another. 

Appliance Powder Coating

Appliances benefit from powder coating because many household appliances deal with moisture or potentially corrosive chemicals on a daily basis.  Refrigerators can be powder coated on the front panels and side panels, which is great because they can become grimy from dirty fingers and need regular cleaning to remain shiny and new.  Without proper coatings, regular cleaning and usage of a refrigerator can have it looking old and worn before its time.  Dishwasher racks are also frequently powder coated to withstand the corrosive detergents and high temperature water required to clean and sanitize dishes.  Water heaters, washer and dryer exteriors, and air conditioner cabinets are also frequently powder coated to protect them and ensure long usage.

Automotive Industry Powder Coating

There are many aspects of the automotive industry that benefit from powder coating.  There is even a new clear top powder coat for the exterior of vehicles, and door handles, bumpers, wheel rims, etc. have been utilizing powder coating in Houston for a long time. Vehicles are subject to the environment on a daily basis, as well as gasoline, oil, and other chemicals regularly. They are also not inexpensive and need to last for years if not a decade or more without falling apart and rusting, and powder coating provides great protection.

In broad terms, there are two types of powder coating in Houston that industries use today.  These are thermoplastics and thermosets. Thermoplastic powder coating is physically bonded to the surface with the introduction of heat.  This requires batch baking that sets the powder coating by turning into liquid form.  Thermoplastic coatings are thicker and tend to be more durable than thermoset powders. Thermoplastic powders are used in a variety of industries, from the automotive industry to the appliance industry and more.  Thermoset powders are chemically bonded to the surface after they are fully cured, which makes them appropriate for use in industries where conditions are harsher, especially temperature because heat will not affect the coating.

Polyvinyl Chloride (PVC)

Polyvinyl chloride powder coating in Houston (PVC for short) is one type of thermoplastic powder. PVC requires a temperature of 400 degrees Fahrenheit to set, so if the underlying substrate is unable to withstand that high temperature, PVC will not be an appropriate coating.  Polyvinyl chloride is FDA approved for use in the food industry.  It is also acceptable to coat chain-link fencing amongst other things.

FUSION BONDED EPOXY FOR WATER PIPELINE INFRASTRUCTURE

Fusion bonded epoxy (FBE for short) and abrasion resistant overcoat (ARO for short) are well known in Houston for their uses in the oil and gas industry. Where they are not well known, however, is in the municipal water industry, such as pipes used to bring drinking water into our homes and sewage pipes and at water treatment plants. The municipal water industry is due for a big upgrade in the next few years. Using fusion bonded epoxy and abrasion resistant overcoats to protect pipes from corrosion will ensure the longevity of the pipes and the health and safety of the region’s residents. Water pipelines can be lined with cement after FBE/ARO applications.

FBE became commercially available in the 1960s, and in the decades since has become a true competitor in the industry for coatings to protect steel pipes and more for the oil and gas industry. It offers great corrosion protection and is environmentally friendly as it involves no solvents. This lack of solvents makes FBE in Houston the perfect option for the municipal water industry. When it comes to drinking water, you have to be careful that the pipes will not leech anything into the water that is hazardous to the health of residents. Typically, pipes are lined with cement mortar and spun at a high rate of speed to compact the mortar to the interior of the pipes. FBE, in combination with ARO coatings, exceeds many standards and requirements for potable water, and the corrosion protection is second to none.

WEATHER-RESISTANT POWDER COATINGS IN HOUSTON

Powder coating provides great protection and durability for many items subject to the elements. To get the best out of weather-resistant powder coatings in Houston, there are certain steps that should be taken to provide optimal protection, especially if refinishing an item that already has a powder coating. 

The first step is to prepare the surface to accept the powder coat. This can be done by media blasting. Media blasting in Houston is the process of using small granules (can be sand, crushed walnut shells, etc.) blown at high speed against an object to remove debris like old paint or rust. This step, where necessary, is vital to the life of the powder coat.

The next step is the actual powder coating application. A primer or rust deterrent can be applied to the surface before the actual powder coat to serve as a foundation. Zinc-rich primers can be used to prevent the formation of rust in humid or wet environments. The powders used in powder coating stick to the surface of the primed metal through electrostatic charge. 

EVERYTHING THERE IS TO KNOW ABOUT POWDER COATING FINISHES IN HOUSTON

What Is Powder Coating?

Simply put, powder coating in Houston is a method of dry coating an industrial product or element to provide protection against rust and corrosion. The powder coating process is superior to the traditional painting process in that it is more environmentally friendly, more durable, and provides a more professional finish. Powder coating can be used on metal, concrete, plastic, and steel and is highly versatile in both application and quality. Unlike traditional paint, powder coatings contain negligible volatile organic compounds (VOCs) typically found in the solvents (the liquid the pigments are suspended in).

What Types Of Powder Coating Are There?

Thermoset and thermoplastic are two types of powder coating. Thermoplastic powder finishes in Houston become soft and melt with the addition of heat. There is no chemical bonding between the metal, plastic, or concrete and the powder. Because of this quality, the powder coating can be recycled and reused. Thermoset powder coatings (such as fusion bonded epoxy) form chemical bonds after it cures, creating a super durable, heat-resistant coating. 

How Durable Is Powder Coating?

Very durable. There is a reason powder coating in Houston is quickly becoming the go-to method for architecture, infrastructure, the oil and gas industry, and even outdoor furniture. Powder coating can protect against corrosion, scratches, extreme temperatures, and more. 

NON-SKID POWDER COATING FINISHES FOR COMMERCIAL BUILDINGS IN HOUSTON

Commercial buildings in large metropolitan areas such as Houston, TX see an inordinate amount of traffic when compared to smaller cities.  With highly populous areas, buildings are typically built up instead of out. While elevators are the main method of going up and down, staircases are necessary for emergencies such as fires or electrical outages. With heavy traffic possible on staircases, it is imperative that non-skid powder coatings in Houston, TX are used to minimize slips and falls of tenants and visitors. Non-skid powder coatings ensure that the treads of the staircase do not become hazardously slippery during a rainstorm or a spill. These special powder coatings can also be applied to stair railings in commercial stairwells to add to the overall safety of the stairwell. 

Non-skid powder coatings in Houston, TX provide all the benefits of traditional powder coating, such as corrosion resistance and durability, while being environmentally friendly. For commercial buildings where handicap accessible ramps are necessary, non-skid powder coatings come in handy for both the disabled and their caretakers. Buildings that require loading ramps benefit from anti-slip ramps for workers and protects packages coming into the building from breaking should an employee fall. Traditional powder coating is beneficial across many industries on its own. With anti-slip properties, your powder coated elements provide protection for your structure and those who may use the structure as a space for their business or home.

PROTECTING COASTAL AND MARINE STRUCTURES WITH POWDER COATING IN HOUSTON

Marine-grade powder coatings in Houston, TX are special powder coatings specifically designed to withstand the harsh, corrosive environment of saltwater and the outdoors. Protecting marine equipment and boating equipment from corrosion, rust, and other issues caused by regular exposure to the marine environment is essential to their durability and safety. Tugboats, cruise ships, commercial fishing vessels, ferries, etc. are all subjected to wind, rain, sun, extreme variation in temperatures, and saltwater on a regular basis. Many aspects of a boat are metal and extremely vulnerable to corrosion, and a simple powder coating process protects the structure and many components for many years. 

The versatility of marine-grade powder coating in Houston, TX allows the smallest the largest components of a boat, marine, or coastal structure to be powder coated and protected from weathering. Direct contact with sea water is not the only risk to corrosion, however, and structures along the coast benefit greatly from marine-grade powder coating. Port structures, dock structures, coastal playgrounds, and coastal commercial or residential buildings will all reap the rewards of marine-grade powder coating in Houston, TX.  

Marine vessels are subject to the exposure of different chemicals, even in clean water, that could also damage the structure without the right protective coating. Different powder coating methods offer different protections, so discussing with Houston Powder Coaters your needs, as well as what your product will be exposed to, is crucial in getting the maximum benefit out of your coatings. Marine-grade powder coatings in Houston, TX create an impermeable barrier between the sea salts and the structure underneath, preventing corrosion before it starts.

POWDER COATING FOR BILLBOARDS IN HOUSTON

In large cities like Houston, thousands upon thousands of billboards line the busy highways and interstates to advertise businesses and organizations. It is a great way to advertise as people drive to and from work, school, the grocery store, etc. However, with the elements and weather subjecting billboards to constant abuse, they can look worn and torn relatively quickly, especially in a city like Houston. 

With powder coating in Houston, TX, the durability far surpasses that of liquid paint. Billboards are particularly susceptible to wind, rain, heat, cold, sun, etc. because they are lifted high into the air making ensuring their durability tantamount. A beat-up looking billboard gives passersby the impression that the business or organization may also be run-down although that is not true. 

Do not think that choosing powder coating in Houston, TX for your billboard will result in limited color options. That could not be further from the truth. Houston Powder Coaters has access to the RAF line of colors and can color match accurately to many other color systems to ensure that colors are accurate from digital media to billboard. 

PROTECTING INFRASTRUCTURE WITH POWDER COATING IN HOUSTON

Infrastructure is a small word that makes up a huge portion of what society sees and uses every day from parking lots to parks, sewage and water collection, electrical systems, transportation systems, and more. What is considered public works is a part of a nation or region’s infrastructure, and because it encompasses such a large portion of everyday life, ensuring durability and longevity is essential to a happy public. 

For playground equipment at public parks, making sure nothing becomes rust-laden is essential for public safety. Powder coating in Houston, TX is environmentally friendly and offers corrosion-resistant coatings in bright colors to suit child minds. Anti-slip powder coatings can be used on steps and pathways too. Parking lot barricades can also be powder coated in bright colors to ensure their visibility to prevent accidents. 

Unlike paint, which will need expensive repainting every few years, powder coating is chip and scratch-resistant and can last for many years.  Even the strongest outdoor paints on the market are susceptible to chipping, and unless sanded smooth during a repaint, previously chipped areas are more likely to chip again. Powder coating in Houston is also resistant to fading in direct sunlight. Most importantly, old and rusted equipment can be media blasted and powder coated to appear new with better protection than it ever had before, and it is more cost-effective than a complete replacement.