Seaside Padel Courts: Epoxy Zinc-Rich Primer + Double-Coat Spray

Constructing a padel court in a coastal city requires extremely high standards for materials and craftsmanship. Due to the long-term effects of sea breezes, salt spray, and high humidity, inadequate protective measures can easily lead to corrosion of the court's steel structure, compromising its service life and safety. This article will explain in depth why epoxy zinc-rich primer + double-coat spray is essential for court protection, focusing on corrosion causes, protection solutions, construction techniques, and actual results.

Challenges of the Coastal Environment for Steel Structures

High Salt Spray Corrosion

Sea breezes contain large amounts of sodium chloride particles. When these salts adhere to the steel surface, they absorb moisture, accelerating oxidation reactions and quickly causing red rust to form.

High Humidity Accelerates Oxidation

Seaside humidity levels range from 70% to 90% year-round. Dew and moisture keep steel moist for extended periods, causing oxidation to occur 3-5 times faster than in inland environments.

Strong UV Light and Temperature Fluctuations

The strong sunlight and large temperature swings between day and night at seaside locations can easily cause cracking and flaking of steel coatings, accelerating corrosion.

UNIPADEL Solution: Multi-layer Protection System

To withstand the harsh coastal environment, we employ the following multi-layer protection processes to ensure the durability, safety, and aesthetics of the court structure:

Epoxy Zinc-Rich Primer

Zinc-Rich Primer contains a large amount of zinc powder, which forms an electrochemical protective layer to prevent oxidation on the steel surface.

Double-layer Powder Coating

Using AkzoNobel powder coating, a base coat is applied first, followed by a top coat. The coating thickness is ≥100 microns, ensuring scratch resistance, UV resistance, and long-lasting color.

Hot-dip Galvanizing

Prior to painting, key components such as columns and crossbars are hot-dip galvanized to achieve a complete metallurgical bond between the zinc layer and the steel, providing long-lasting corrosion protection.

Construction Process

To ensure uniform and secure coating adhesion, the construction of padel courts requires strict procedures:

1. Steel Pretreatment

• Black carbon steel is welded and formed.
• Fine grinding and shot blasting are performed to remove scale, weld slag, and burrs.
• Ensure the surface roughness is suitable for coating adhesion.

2. Hot-Dip Galvanizing

• Immersing the steel structure in hot zinc bath forms a dense, uniform zinc barrier.
• Further grinding ensures a smooth surface.

3. Spraying Epoxy Zinc Primer

• Apply an even first coat of epoxy zinc primer.
• Cure at a low temperature to ensure the primer penetrates the pores of the steel surface.

4. Double-Coat Powder Coating

• Apply the first coat of powder coating → Bake and cure.
• Apply the second topcoat → Bake again to achieve a high-strength coating.

Finished Product and Service Life

After completing these processes, the steel structure exhibits a smooth, vibrant color with the following advantages:

• Salt spray corrosion resistance of up to 1000 Over 10 hours of playtime.
• Structural strength is unaffected by sea breeze erosion.
• The surface is wear-resistant and scratch-resistant, allowing for simple daily maintenance.
• A stable service life of over 8 years is expected.

Padel courts built near the sea without adequate corrosion protection measures can suffer from rust, paint peeling, and even safety hazards within a few years. Our multi-faceted treatment process of epoxy zinc-rich primer, double-layer powder coating, and hot-dip galvanizing not only enhances the court's aesthetics but also significantly extends its service life, reducing maintenance costs for investors and ensuring player safety and a positive experience.