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Powder coating is a well-known finishing technique, but very few coating companies in Australia have the capability to handle oversized structures. At Superior Coaters, we’ve built our facility—and our reputation—around large-scale projects that require precise engineering, consistent quality, and rigorous attention to detail.
In this article, we’ll take you behind the scenes of how we manage the powder coating of structures up to 14 metres long, including our facility setup, workflow, equipment, and quality assurance process. Whether you’re coating architectural steel, commercial shade frames, or utility infrastructure, this is what it takes to get it right—every time.
Why Size Matters in Powder Coating
Larger steel structures introduce a unique set of challenges:
- Uniform coverage over extended surface areas
- Controlled curing across different thicknesses and materials
- Safe handling and support to avoid warping or damage
- Precision blasting and preparation that scales with size
Traditional powder coating facilities often max out at 6–8 metres. That’s fine for fences or balustrades—but not for the large-scale architectural and commercial projects we’re known for. To meet this demand, we’ve invested heavily in equipment and systems that support coating at scale.
We’re proud to be one of the few facilities in Queensland offering oversized powder coating up to 14 metres—a fact we explore further in our article on Oversized Powder Coating Solutions.
Step 1: Receiving and Inspection
Every project starts with receiving the steel components at our facility. We inspect all materials for:
- Surface condition (rust, oil, contaminants)
- Weld quality and sharp edges
- Material identification (aluminium, mild steel, galvanised, etc.)
This inspection is crucial because the success of powder coating relies heavily on the surface preparation phase. Any defects or inconsistencies need to be addressed before blasting begins.
For more on material types and the impact on coating longevity, check out How to Choose the Right Industrial Coating System.
Step 2: Surface Preparation in Oversized Blast Booths
Next, items are transferred to our oversized blasting booth where we perform abrasive blasting to achieve the required profile—typically a Class 2.5 near-white metal finish. This creates the ideal mechanical anchor for powder adhesion.
For oversized components, achieving consistency is harder—especially on inside welds, curved tubing, and large flat surfaces that are prone to flash rust if left untreated too long.
That’s why we move swiftly from blasting to coating to lock in surface integrity and ensure a durable finish. Preparation is a key topic in our blog on Working at Scale: Powder Coating for Massive Shade Structures, which gives insight into real-world applications of this process.
Step 3: Powder Application in a Custom 14 Metre Booth
Once cleaned and ready, structures are moved into our custom-built powder coating booth. At 14 metres long, it allows for single-pass coating of even the largest beams, columns, or frames—eliminating seams or joins that might otherwise compromise finish quality.
We apply powder using electrostatic spray guns, allowing the powder to bond evenly across intricate surfaces. Oversized structures often require:
- Multiple operators to ensure even coverage
- Controlled humidity and airflow to avoid contamination
- Tailored powder formulations for edge retention and UV resistance
We use high-performance products from brands such as Interpon and Dulux, and we’re proud to be an accredited Dulux Steelshield® applicator, ensuring coating warranties on structural steelwork.
Step 4: Curing in Our Purpose-Built Oven
One of the most distinctive features of our facility is our industrial oven built specifically for oversized workpieces. At full capacity, we can cure powder-coated structures up to 14 metres long, ensuring the heat profile is uniform from end to end.
Consistent curing is what transforms powder into a hard, protective layer that resists UV damage, chipping, and corrosion. Curing times and temperatures are adjusted based on:
- Powder type (polyester, epoxy, hybrid)
- Material thickness
- Complexity of the component geometry
Learn more about our facility’s capabilities in the article Powder Coating Oversized Steel? Here’s What to Know, where we detail common misconceptions around heat tolerance and curing.
Step 5: Quality Control and Testing
After cooling, each item undergoes a thorough quality check. This includes:
- Visual inspection for uniformity and surface defects
- Film thickness testing using digital gauges
- Adhesion testing, if required for warranty
- Packaging and protection for safe transport
We maintain strict adherence to AS/NZS 4506 and ISO 12944 standards for corrosion protection and surface finish. It’s part of what sets us apart as a leader in the industrial powder coating space.
Step 6: Delivery or Onsite Coordination
We work closely with fabricators, builders, and installers to coordinate delivery or onsite pickup. For large or awkward pieces, we often assist with:
- Custom cradles or supports for transport
- Protective wrapping to prevent damage in transit
- Flexible pickup schedules to suit tight build timelines
Because we specialise in commercial and infrastructure projects, we understand the demands of the construction pipeline. Our goal is to deliver not just a coated product, but peace of mind.
Trusted by Industry Leaders
We’ve coated oversized components for:
- Commercial awnings and shade structures
- Public infrastructure such as handrails and poles
- Transport and mining sector equipment
- Custom architectural fabrications
In projects like the Bridgeman Downs architectural canopy, featured in our Working at Scale article, our large-format capability made all the difference in delivering a high-quality result that was on time and on budget.
Why Choose Superior Coaters for Oversized Powder Coating?
- One of the largest coating ovens in Queensland
- 14m blasting, coating, and curing capacity
- Steelshield® accredited for structural warranties
- Custom logistics support for large builds
- Unmatched experience in architectural and industrial projects
When it comes to scale, precision, and reliability, we’re not just a coating provider—we’re your project partner.
Want to learn more about what goes into powder coating large structures? Explore our full blog at superiorcoaters.com.au/blog or get in touch to talk through your upcoming project.
