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The Manufacturing Process of Vitreous Enamelled Steel Vanity Tops and Sanitary Ware.



Importing

The bath and shower tray steel shells are imported from Europe and enamelled in South Africa

Steel Preparation

Every bath and shower tray goes through a chemical process to remove contamination and provide an 'etched' surface to receive the enamel. The special low-carbon steel is chemically pretreated, which involves alkaline degreasing, acid pickling and surface passivation to ensure 100% adherence for the glass coating.

Ground Coating

The first coat, or ground coat, is applied to all surfaces.


Furnace

The ground coat is dried at 200 - 300ºC leaving the enamel in a 'bisque' form on the steel.
Baths and shower trays are pre-heated to 400ºC before entering the furnace.
The chemical fusing of the vitreous enamel to the steel base takes place at approximately 820ºC. Upon firing in the furnace, under closely controlled conditions, each coat is chemically bonded to the steel base. The powder melts, flows and hardens to a smooth, durable vitreous coating on the metal.


Top Coats

Subsequent colour coats are applied (usually 2) depending upon the specification.
The second coat or cover coat is specially formulated with, for example, titanium-based frits, suspending agents and ceramic pigments to provide chemical resistance, abrasion and wear resistance, colour and texture. It is applied in the same way as the ground coat and is once again fired at 820ºC. After two cover coat layers, the overall thickness of the coating is increased to 250-350 microns (1 micron = a millionth of a millimetre).


Accessories

The handles and waste outflow is fitted


Inspection

Baths and shower trays are cleaned, inspected to ensure that there are no defects and then bubble-wrapped.


Packaging

Packed for transportation.