Powder Coating Process & QA/QC
In-house powder coating with quality control for durable, long-lasting finishes.
5402 184th St E, Puyallup, WA 98375
Powder coating provides a durable, attractive finish superior to wet paint in most applications. Our in-house line allows us to control quality and match colors precisely.
What We Do
- Surface preparation (sandblasting, chemical prep)
- Primer application when required
- Powder coating in standard and custom colors
- Curing at proper temperature and duration
- Thickness and adhesion testing
- Touch-up and repair coating
Best Fit For
- New gate and fence fabrication
- Architectural color matching requirements
- Projects specifying AAMA 2603, 2604, or 2605 finishes
- Refinishing of existing metalwork
- Contractors requiring coating services
How We Deliver
- Color selection and matching
- Surface preparation appropriate to substrate
- Electrostatic powder application
- Controlled oven curing
- Quality inspection and testing
- Protection and packaging for transport
Standards & Compliance
- AAMA 2603/2604/2605 specifications
- Mil thickness requirements
- Adhesion testing (cross-hatch)
- Color consistency verification
What Is Powder Coating
Powder coating is a dry finishing process that uses finely ground particles of pigment and resin, electrostatically charged and sprayed onto metal surfaces. The charged particles adhere to the grounded metal, then the coated piece enters an oven where heat fuses the powder into a smooth, durable film.
Unlike wet paint, powder coating contains no solvents and releases negligible volatile organic compounds. The process is cleaner and more environmentally friendly. Overspray can be collected and reused, reducing waste.
The result is a finish more durable than most paints. Powder coating resists chipping, scratching, fading, and wearing. For gates and fences exposed to weather and use, this durability matters.
Surface Preparation
Powder coating is only as good as the surface beneath it. Preparation removes contaminants, mill scale, rust, and previous coatings that would prevent adhesion or cause failures. Skipping or shortcutting preparation leads to coating failures.
Sandblasting is our primary preparation method. Media propelled at high pressure removes surface contamination and creates profile,microscopic texture that improves coating adhesion. Different media and pressures suit different substrates and conditions.
Chemical preparation supplements or replaces blasting for certain applications. Phosphate conversion coatings provide additional corrosion protection and improve adhesion. Aluminum requires different preparation than steel. We match preparation method to substrate and specification.
- Sandblasting to remove scale, rust, and contamination
- Profile creation for mechanical adhesion
- Chemical conversion coatings when specified
- Substrate-specific preparation methods
- Inspection before coating application
Powder Application
Application uses electrostatic spray guns that impart positive charge to powder particles. The grounded workpiece attracts the charged powder, which adheres uniformly across surfaces, including hard-to-reach areas. The electrostatic attraction wraps powder around edges and into recesses.
Application technique affects coating quality. Gun settings, powder flow rate, distance from workpiece, and spray pattern all influence the result. Our applicators develop these skills through training and experience.
Multiple coats may be required for certain specifications or colors. Primers improve adhesion and corrosion protection on steel. Topcoats provide color and UV protection. Two-coat systems offer performance that single coats cannot match.
Curing Process
Heat transforms powder particles into continuous film. Curing occurs in controlled ovens at temperatures and durations specified for each powder chemistry. Undercuring leaves soft, weak films. Overcuring can damage color and properties.
Different powders require different cure schedules. Polyester powders typically cure at 375-400°F for 10-20 minutes at metal temperature. Fluoropolymers require different schedules. We maintain records of cure schedules for each powder we use.
Part size and mass affect cure time. Large, heavy parts take longer to reach cure temperature than small, thin parts. We monitor part temperature to verify adequate cure, not just oven temperature and time.
Color Options
Standard colors cover most needs. We stock popular colors for immediate use, blacks, whites, bronzes, and common architectural colors. Standard colors mean no lead time for powder procurement.
Custom colors are available for any specification. RAL numbers, Pantone matches, or physical samples can all be matched. However, custom powder is not like paint—it cannot be mixed on site. Custom colors must be manufactured to order, which means minimum quantity requirements (often 50+ pounds), lead times of several weeks, and significantly higher costs than stock colors. For small quantities of a specific color, custom matching may not be practical or economical.
Textures and effects extend beyond smooth finishes. Textured finishes hide minor surface imperfections and reduce visible fingerprints. Metallic effects add depth. Hammer-tone, wrinkle, and other specialty textures serve specific aesthetic goals.
Quality Testing
We verify coating quality through standard industry tests. Thickness measurement confirms adequate coverage. Adhesion testing confirms the coating is properly bonded to the substrate. Visual inspection confirms appearance meets standards.
Thickness is measured with electronic gauges that read coating depth without damaging the finish. We check multiple locations on each piece. Specifications typically require minimum thickness; we verify compliance.
Adhesion testing scores the coating in a crosshatch pattern, then applies and removes tape. Properly adhered coating remains intact. Poor adhesion shows lifting or peeling. We test representative pieces from each batch.
AAMA Specifications
AAMA (American Architectural Manufacturers Association) specifications define coating performance levels. These specifications are commonly referenced for architectural metalwork, including gates and fencing.
AAMA 2603 is the basic specification, suitable for mild environments with limited UV exposure. It requires polyester powder with one-year South Florida exposure testing. Most residential and light commercial work meets 2603.
AAMA 2604 requires higher performance with five-year exposure testing. It uses improved resins for better weathering. AAMA 2605 requires fluoropolymer coatings with ten-year exposure testing,the highest performance level for extreme environments.
- AAMA 2603: Basic performance, one-year Florida exposure
- AAMA 2604: High performance, five-year exposure
- AAMA 2605: Superior performance, ten-year exposure with fluoropolymers
Refinishing and Repair
Existing metalwork can be refinished with powder coating. Old gates, fences, and components can be stripped, prepared, and recoated to extend their life and improve appearance. Refinishing costs less than replacement while achieving like-new results.
Repair coating addresses damage to existing powder coat finishes. Touch-up paint handles small scratches and chips. Larger damage may require partial or complete recoating. We assess damage and recommend appropriate repair.
Preparation for refinishing may be more intensive than new work. Old coatings must be removed completely for best results. Chemical stripping or aggressive blasting removes old finishes. The clean metal then receives the same preparation as new material.
Frequently Asked Questions
- What is the difference between AAMA 2603 and 2605?
- AAMA 2603 is a basic performance specification suitable for mild environments. AAMA 2605 is a high-performance specification for harsh environments, requiring fluoropolymer coatings with superior weathering resistance.
- Can you match existing colors?
- Many colors can be closely matched with existing products from our distributors. Custom matching can also be accomplished, but the costs are significantly higher and may not be economically feasible for smaller projects.
- How long does powder coating last?
- Properly applied powder coating on properly prepared surfaces lasts 15-20 years or more in typical conditions. UV exposure, salt air, and chemical exposure reduce lifespan. AAMA 2605 fluoropolymer coatings offer the longest color retention and weathering resistance.
- Can damaged powder coating be repaired without recoating the entire piece?
- Small chips and scratches can be touched up with matching paint. Larger damage may require partial or complete recoating. Touch-up paint does not have the same durability as factory powder coat, but protects the substrate and improves appearance until full refinishing is practical.
Related Services
Custom metal fabrication for gates, fencing, and related components.
Architectural-grade ornamental fencing combining aesthetics with security for commercial properties, residential estates, pool enclosures, and public spaces.
Fence and gate repair, modification, and upgrade services,from storm damage repairs to security enhancements and automation retrofits.
Code compliance and permitting information.
Ready to Get Started?
Request a quote for your commercial, industrial, or residential project.