Pole Info Center

Our optional 5-year finish warranty provides an even greater level of corrosion protection with the addition of an internal rust inhibitor.

For detailed information about what our workmanship and manufacturer’s warranty covers, see Section XI of our Terms and Conditions of Sale.

STAGE 1: Cleaning

The overall success of our state-of-the-art finishing process depends entirely on the quality of the product at the beginning of the process. All products are first inspected for visible deposits of oil, grease, or other contaminants. Surface imperfections such as sharp fins and edges, weld spatter, or burning slag are removed. Once any visual imperfections have been addressed, the piece is sent to our four-wheel shot blaster system, specifically designed for the cleaning steel and aluminum poles. We use steel shot to remove any rust, mill scale, oxides, or other unwanted particles from the shaft or bracket. Upon exiting the shot blaster, compressed dry air is used to remove any remaining shot. The quality of our inspections, shot, and equipment result in a surface preparation that exceeds the specifications published by the SSPC-SP10.

STAGE 2: Phosphate Rinse (Steel Poles Only)

In this stage, the pole is coated with iron phosphate, which creates an iron oxide base followed by a flat or amorphous metal phosphate topcoat. This phosphating, or conversion coating, is a critical part of the pretreatment process for steel poles, adding significantly to the performance of the finished coating. A phosphate coating converts the metal substrate to a uniform, inert surface, which improves bonding, minimizes the spread of oxidation if the coating is scratched, and improves the overall corrosion resistance of the final part.

STAGE 3: Powder Coat Application (6 MILS)

The 6 mils of powder coating supplied with this warranty level provides excellent corrosion protection from environmental elements. Powder coating is also environmentally friendly since the process emits zero or near zero volatile organic compounds (VOC). The powder used is a triglycidyl isocyanurate (TGIC) polyester specially formulated for General Structures, Inc. This formula consists of polymers, pigments, and fillers that form a fine dry powder for electrostatic application. The electrostatic application is performed automatically by the negative charging of the powder at high voltage, low amperage, and electrically grounding the pole. This creates a magnetic effect that enables the powder to be applied consistently and uniformly to all exposed surfaces of the pole. Powder coating provides superior edge coverage and creates a high-quality, durable finish with virtually no drips, runs, or sags.

STAGE 4: Curing

Once the powder is applied, the pole then moves to the curing process. We cure powder using a unique combination of infrared and convection heat. The pole is heated to temperatures exceeding 450°. When the powder is exposed to this heat, it begins to melt, flows out, and then chemically reacts to form a higher molecular weight polymer in a network-like structure. This curing process, called crosslinking, requires a certain temperature for a certain length of time in order to reach full cure and establish the full film properties for which the material was designed.

STAGE 5: Palgard Epoxy Coating

With this warranty level, we offer an internal rust inhibitor. As an added layer of protection against the elements, this Palgard Epoxy coating is applied to the internal wall of the shaft using an airless spray gun or roller. This two-component, high-gloss coating is formulated to provide a hard, chemical, and solvent-resistant finish.

STAGE 6: Blue Wrap

Once completely cooled, the pole is then sent to be wrapped in our signature Blue Wrap — a multi-layered, UV- and tear-resistant, vinyl bubble wrap designed to ensure the products reach the job site in top condition.