1.What is the production process?
Uncoiling and Straightening: The galvanized coil is unwound and passed through a straightener to flatten it.
Entry Section: The strip is introduced into the rolling mill.
Roller Embossing: This is the core step. The flat galvanized sheet passes through one or more pairs of specially designed patterned rollers.
Upper Roller: Engraved with a raised pattern.
Lower Roller: Typically smooth or with matching grooves.
Under tremendous pressure, the pattern on the upper roller is pressed into the surface of the galvanized sheet, creating a uneven pattern.
Cut-to-Length: The continuous patterned sheet is cut to specified lengths as required.
Collecting/Stacking: The finished sheets are collected into stacks.
2.What are the advantages of the process?
Effective corrosion protection: The base plate itself is a galvanized coil, and the zinc layer provides long-lasting sacrificial protection for the steel. After the patterned plate is produced, no additional electroplating or hot-dip galvanizing is required, saving time and effort.
Cost-effective: Compared to first producing the patterned plate and then applying anti-corrosion treatment (such as spraying), using the galvanized base plate directly shortens the process and reduces overall costs.
Excellent integrity: The zinc layer and the pattern are integrated, eliminating the potential for coating detachment that can occur with subsequent spraying.
Increased strength and rigidity: The resulting pattern is not only aesthetically pleasing and non-slip, but also acts as a "rib," enhancing the plate's mechanical strength and flatness, making it less prone to deformation.
3.What is the impact of the zinc layer?
Positive side: The zinc coating is generally softer than pure steel, which can sometimes facilitate embossing and reduce wear on the rollers.
Negative side: During the embossing process, the zinc coating in the concave and convex areas is subjected to significant stretching and compression. While the zinc coating has good ductility, it may develop microscopic cracks or thinning at sharp corners or edges. This generally doesn't immediately affect corrosion protection, but theoretically, there will be a slight decrease in corrosion resistance at these locations.
4.What should we pay attention to when choosing a substrate?
Material: Typically made of low-carbon steel base galvanized coils, offering good formability.
Zinc Coating Type: Options include pure zinc plating (GI) or zinc-iron alloy plating (GA). Zinc-iron alloy plating is harder and more wear-resistant, but its formability is slightly worse than pure zinc plating, and it is more prone to micro-cracks during embossing.
Surface Finish: Options include smooth or matte galvanized coils. Smooth finishing improves surface quality, resulting in clearer and more aesthetically pleasing patterns.
5.What are the common application areas?
Construction:
Walkways, industrial platforms, and stair treads: Anti-slip performance is paramount.
Warehouse floors and racking: Enhanced rigidity and wear resistance.
Interior and exterior building decoration: Walls and ceilings, for example, utilize their unique texture for decorative effects.
Transportation:
Floors of trucks, containers, and trucks: Anti-slip and durable.
Steps on buses and trains.
Industrial equipment:
Housings and platforms of various machines.
Household appliances:
Bottom covers of some refrigerators and washing machines, etc.