Ramps/Railings
This project highlights the powder coating of physical therapy ramps and railings fabricated for a national biotech company whose clients rely on these installations to rebuild confidence and mobility. The ramps will play a vital role in helping individuals with new prosthetic legs navigate slopes, strengthen their gait, and adapt to real-world conditions safely and effectively.
Process Overview:
- Racking: Securely mounting ramps and railings for full-coverage access.
- Sandblasting & Surface Prep: Abrasively cleaning all metal surfaces to remove rust, oxidation, and contaminants from fabrication and storage.
- Washing & Chemical Pre-Treatment: Applying enhanced cleaning and conversion coatings for superior powder adhesion.
- Drying: Controlled dehydration to prevent moisture interference during coating.
- Powder Coating: Applying an electrostatically charged powder layer for consistent color and coverage.
- Curing: Baking the coated parts at precise temperatures for a durable, bonded finish.
- De-Racking & Palletizing: Carefully removing and organizing finished parts for delivery and installation readiness.
Each stage reflects our commitment to quality, performance, and longevity, ensuring that the final product not only looks exceptional but stands up to the high-demand environment it was built for.
Racking
Setting the Foundation for a Flawless Finish
The first step of the process begins with racking — the unsung foundation of a superior powder coat. For this project, our team utilized custom-designed racks engineered specifically to hold ramps and railings of varying sizes and geometries.
These custom racks allow for maximum accessibility throughout every stage of the finishing process — from chemical pre-treatment to coating and curing — ensuring that every angle, edge, and weld receives full and even exposure. The design also minimizes contact points, preventing imperfections or missed areas during coating, and promotes efficient airflow during curing for consistent temperature distribution.
By investing in tailored racking systems, we not only optimize coating uniformity and adhesion but also streamline handling, reduce turnaround time, and improve overall finish quality. It’s the kind of attention to detail that sets a professional powder coating operation apart — precision and efficiency from the very first step.
Surface Preparation
Building the Perfect Base
Once the ramps and railings are securely mounted, the next critical stage is surface preparation — a process that defines the quality and longevity of the final finish. In this specific case, our technicians use sanding and buffing techniques to remove oxidation, mill scale, and surface contaminants that may have developed during fabrication or storage.
This step isn’t just about cleaning; it’s about engineering the right surface profile for maximum powder adhesion. Steel is filthy by nature and needs special attention. Ideally sandblasting would be used to prepare the surface, but for an indoor use item such as these, an acid wash will suffice for prep.
Following racking and surface prep, the parts are inspected for integrity and consistency before moving into the chemical pre-treatment and washing stage. The result is a perfectly prepped surface — clean, and ready to accept a flawless, corrosion-resistant powder coat that’s built to last.
Washing & Chemical Pre-Treatment
Engineering Adhesion and Corrosion Resistance
After sanding and buffing, each ramp and railing moves into a critical refinement stage — washing and chemical pre-treatment. Commonly referred to as an acid wash, this process ensures that every surface is not only spotless but chemically conditioned for maximum coating performance.
To guarantee the highest quality adhesion and corrosion resistance, we utilize an enhanced five-stage wash system that incorporates the latest in zirconium conversion coating technology. This advanced system surpasses the performance of traditional iron phosphate methods, delivering superior salt spray results compliant with AAMA 2604 — the industry standard for long-term durability in harsh environments.
Our zirconium pretreatment is applied by heated pressure wand or foam cannon, using heat to drive out any residual oils or soils and ensure a completely water-break-free surface. The zirconium coating chemically bonds to the metal, forming a nano-layer that:
- Improves adhesion of the powder coating to the substrate
- Increases resistance to corrosion, rust, and environmental wear
- Prepares the metal for a flawless, long-lasting finish
- Excels in heavy-duty, automotive, and outdoor applications
By combining our zirconium chemical pretreatment with precise abrasive surface preparation, we create a foundation built for performance — ensuring every ramp and railing achieves a finish that exceeds AAMA 2604 standards and is ready to withstand real-world use in the biotech training environment.
(For a deeper dive into the science behind conversion coatings and their role in modern powder coating performance, check out our upcoming technical articles.)
Drying
Eliminating Moisture for a Perfect Coating
Following the washing and chemical pretreatment stage, each ramp and railing undergoes a carefully controlled drying process — a crucial step to ensure the success of the final powder coating application. Even trace amounts of moisture can interfere with adhesion, causing imperfections such as bubbling, pinholes, or uneven coverage.
To prevent this, our team performs controlled dehydration using a combination of forced air circulation and timed oven exposure. This ensures that every component reaches a consistent, moisture-free state before entering the coating booth. By allowing the parts to stabilize thermally, we eliminate residual humidity that could compromise powder adhesion or finish quality.
The result is a completely dry, pre-heated surface — clean, stable, and ready to receive an even electrostatic powder application. This attention to environmental control not only enhances coating performance but also contributes to long-term durability and resistance under demanding real-world conditions.
Powder Coating
Durable Beauty Meets Clinical Precision
With every ramp and railing fully prepped and moisture-free, the next phase — powder coating — transforms the raw metal into a finished surface that’s both visually refined and engineered to endure.
Powder coating is the gold standard for achieving durable, long-lasting finishes that resist chipping, fading, and corrosion. For this project, a clean white powder coating was selected to complement the modern, clinical environments of the biotech company’s training facilities — bright, hygienic spaces where aesthetics and function must align seamlessly.
Our team provides a wide range of powder coating options in endless color selections to meet the specific requirements of any project — from industrial equipment and architectural components to automotive and power sports applications. Each coating is applied through an electrostatic process, ensuring smooth, even coverage across every surface.
Our powder coating process delivers:
- Chip-resistant, high-performance finishes for heavy-use environments
- Custom color options tailored to brand or design requirements
- Durable protection from rust, corrosion, and UV fading
- High-quality consistency and a refined, Class A finish every time
This combination of precision application and controlled curing guarantees that every ramp and railing not only looks pristine but performs flawlessly — embodying the strength, cleanliness, and confidence central to the client’s mission.
Curing
Heat-Bonded Strength That Lasts
Once the ramps and railings are evenly coated, they enter the critical curing stage, where science and craftsmanship meet to create the final, durable finish. During this phase, the powder-coated parts are baked at precise, controlled temperatures that allow the powder particles to melt, flow, and chemically bond into a continuous, solid film. Most powders cure at 400 degrees for 10 minutes at part metal temp.
Our facility is equipped with two massive industrial natural gas ovens, each capable of accommodating projects of various scales — from intricate rail systems to large structural fabrications. This capacity allows us to maintain consistent curing cycles while managing high-volume production efficiently.
Temperature control and timing are essential to achieving the ideal cross-linking reaction that gives powder coating its legendary toughness. Each component is monitored throughout the process to ensure that the coating fully bonds with the substrate, producing a uniform, high-gloss finish that resists impact, abrasion, corrosion, and fading.
The result is a durable, bonded finish that not only meets but exceeds industry performance standards — a coating built to withstand the demanding, real-world use these ramps and railings will experience in the biotech rehabilitation environment.
De-Racking & Palletizing
Ready for Delivery and Installation
After curing, each ramp and railing is allowed to cool before moving into the de-racking and palletizing stage — the final step before delivery. Our technicians carefully remove every component from the custom racks to protect the newly finished surfaces and maintain the integrity of the Class A powder coat finish achieved through earlier stages.
Each part is inspected for coating consistency, surface smoothness, and color uniformity, ensuring it meets both our internal quality standards and the expectations of the client. Once verified, the ramps and railings are strategically organized and palletized for efficient transport and installation readiness.
This final stage completes the journey from raw metal to finished product — a series of precision-driven steps designed to deliver durable, high-performance, and visually pristine components ready to serve their purpose. From racking to final loading, every detail reflects our commitment to craftsmanship, consistency, and long-term durability.
Powder coating is the gold standard when it comes to durable, long-lasting finishes. We provide a wide range of powder coating options in endless color selections to match the specific requirements of your project. Whether it’s for industrial equipment, automotive parts, or power sports applications, our powder coatings deliver:
- – Chip-resistant, high-performance finishes
- – Custom color options to match your brand, aesthetic, or personal style
- – Durable protection from rust, corrosion, and fading
- – High-quality, consistent results every time
- – Available in smooth, matte, textured, metallic, and more
- Why Choose Adrenaline Customs?
- — Class A Finish Capabilities – High-end finishes that look and perform like no other.
- – Endless Color Selections – We offer a wide range of color options to suit any project, from bold to subtle.
- – Fast Turnaround – We understand the importance of deadlines and work quickly while maintaining the highest quality standards.
- – Excellent Customer Service – From the initial consultation to job completion, we provide exceptional service, clear communication, and support every step of the way.
- – Eco-Conscious Materials – We use high-quality, eco-friendly materials that protect the environment without compromising durability or performance.
- – Precision & Reliability – Whether it’s one part or hundreds, we ensure every job is done right the first time.
Adrenaline Customs, providing powder coating and blasting to Minneapolis and St. Paul MN since 2008.