I. Core Advantages of Art Padel’s Process
1. Comprehensive Upgrade of Corrosion Resistance
Advantage in Galvanized Coating Thickness:
The thickness of the galvanized coating exceeds 50um (while other processes usually only reach around 30um). In Art Padel’s hot-dip galvanizing process, after drilling and welding, the entire metal frame is immersed in a liquid zinc solution at 500 degrees Celsius. The high-temperature liquid zinc has strong penetration ability, forming a dense and uniform thick coating on the metal surface. According to international standards (such as ISO 1461), for every 10um increase in thickness, the corrosion resistance in salt spray tests increases by approximately 50%. A 50um coating can withstand more than 800 hours of salt spray testing (Art Padel’s 800-hour salt spray test report is available for sharing), making it suitable for outdoor humid environments and extending the service life by 2-3 times compared to other processes.
Full-Surface Coverage without Dead Zones:
Processing first and then galvanizing ensures that all processed areas, including cut surfaces and drilling edges, are completely covered by the coating, preventing the exposure of the steel substrate. In actual operation, immersing the entire metal frame in the 500-degree Celsius liquid zinc solution after drilling and welding allows the zinc liquid to fully fill the welding seams and the inner walls of the drilled holes, creating a complete protective layer. However, some manufacturers directly purchase pre-galvanized steel pipes for production. During subsequent drilling and welding processes, the galvanized coating on the metal surface is damaged. The exposed steel substrate and the remaining coating create a potential difference, accelerating electrochemical corrosion. Even with touch-up galvanization, it is difficult to achieve the integrity of overall hot-dip galvanization (the adhesion between the touch-up coating and the hot-dip galvanized layer is poor and prone to peeling). Corrosion of the metal structure usually starts at these weak points, leading to problems during later use.
2. Optimization of Surface Quality and Safety
Deburring after Galvanization:
Zinc nodules and burrs generated during the hot-dip galvanization process are removed through grinding, reducing the surface roughness (Ra≤6.3μm). This prevents scratches to operators and wear on components during installation. If the approach of galvanizing first and then processing is adopted, due to the low hardness of the galvanized layer (HV 180-220), the coating in non-machined areas is easily damaged during grinding.
II. Core Differences between Art Padel’s Process and Other Processes
| Comparison Dimension | Art Padel’s Process(Process First, Then Galvanize + Grinding) | Other Manufacturers’ Common Process(Galvanize First, Then Process) |
| Process Sequence | Purchase steel pipes → Processing (cutting/drilling) → Welding → Hot-dip galvanization → Deburring | Purchase pre-galvanized steel pipes → Processing (cutting/drilling) → Welding → Possible touch-up galvanization |
| Coating Integrity | After processing, the entire frame is immersed in 500°C liquid zinc, achieving full-surface coverage. Welding points and drilled holes are completely coated without any exposed areas | Processing and welding damage the original galvanized coating, requiring touch-up galvanization (resulting in inconsistent coating thickness and poor adhesion) |
| Coating Thickness | 50μm+, uniformly covered | Original coating of pipes is around 30μm; inconsistent thickness after touch-up galvanization in processed areas |
| Surface Treatment | Deburred after galvanization, free of zinc nodules and burrs, smooth surface | Machining may generate new burrs; the galvanized surface may be scratched during processing |
| Corrosion Resistance | Salt spray test > 800 hours; no anti-corrosion maintenance required within 10 years | Uncoated areas will rust within 2-3 years; salt spray resistance is about 500 hours after touch-up galvanization |
| Cost and Efficiency | Slightly higher galvanization cost (due to thick coating + grinding), but reduces later maintenance | Lower initial cost for purchasing pre-galvanized pipes, but touch-up and maintenance costs increase by 20%-30% |
| Application Scenarios | High-requirement outdoor facilities (such as padel courts), long-term weather resistance | Indoor dry environments or scenarios with low anti-corrosion requirements |
III. Targeted Advantages of Art Padel’s Process for Padel Courts
1. UV Resistance and Climate Aging Resistance:
The thick galvanized layer combined with a smooth surface reduces UV oxidation. In high-temperature and rainy regions (such as tropical areas), it maintains excellent corrosion resistance, avoiding issues like powdering and peeling caused by thin coatings.
- Improved Installation Compatibility:
The ground surface of the steel pipes is flat, ensuring better sealing during bolt connections and preventing rainwater from seeping into the connection gaps. If the cut edges are not touch-up galvanized, rainwater will corrode the inner part of the steel pipes through threaded holes.
- Aesthetics and Brand Value:
The uniform, burr-free galvanized surface enhances the overall texture of the court, meeting the visual requirements of high-end sports venues. It has a stronger market competitiveness compared to processes with “scars in processed areas”.
IV. Conclusion
Through the process combination of “processing first, then galvanizing + thick coating + grinding”, Art Padel has achieved significant advantages in corrosion resistance, surface quality, and structural safety, especially fitting the strict weather resistance requirements of outdoor padel courts. Compared with processes of galvanizing first and then processing or directly using pre-galvanized pipes for processing, the latter are more suitable for low-requirement scenarios due to defects such as thin coatings and damage to the anti-corrosion layer during processing. There are obvious differences in long-term use costs and performance between the two types of processes.
Contact Art Padel now:
Tel: +86 532 68978909
WhatsApp/Wechat/Tel: +8619050566530
Email: art02@artpadel.com
Web: www.artpadel.com
