Project Overview
Client: A Leading Metals & Steels Enterprise (Mussafah Industrial Area)
Location: Abu Dhabi, United Arab Emirates (UAE)
Equipment Supplied: Superbake Industrial Paint Booth (Model: KT-PQ-III-PLUS)
Application: Surface finishing and protective coating for large-scale steel structures and heavy industrial components.
The Client's Challenge
The client, operating a major metal and steel fabrication facility in Abu Dhabi, required a turnkey surface finishing solution for oversized industrial parts. However, the project presented several unique engineering and logistical challenges:
Oversized Workpieces:
Standard automotive booths were insufficient. The client required a massive internal working envelope with high-clearance doors for heavy machinery access.
Extreme Climate Conditions: The ambient temperature in the UAE can exceed 45°C (113°F) during the summer. The booth's HVAC and ventilation system needed to maintain optimal airflow and prevent premature paint drying without overloading the local power grid.
Strict Safety & Compliance: Due to the volatile nature of industrial coatings, the client mandated rigorous explosion-proof standards for all electrical and lighting components (equivalent to Q/FD 4 / IP65 compliance).
High Local Labor Costs: Executing heavy civil foundation works utilizing an overseas installation team would incur prohibitive costs for the client.
The CoatTech Solution
Our engineering team designed a highly customized iteration of our KT-PQ-III-PLUS Superbake Paint Booth to meet the specific demands of the Middle Eastern market.
1. Heavy-Duty Structural Design
We expanded the internal dimensions to 8000 × 5000 × 4500 mm (L×W×H) and equipped the booth with a reinforced, sheet-metal folding main door (4400 × 4400 mm) to easily accommodate large steel structures. The cabin was constructed using 70mm high-strength insulated EPS wall panels to ensure excellent thermal retention and structural integrity.
2. Upgraded Explosion-Proof Safety
To meet the strict safety protocols of the UAE industrial sector, we implemented a fully sealed IP65 Explosion-Proof Lighting System. This included 80 specially housed 22W T8 LED tubes with double-layer explosion-proof sealing gaskets, entirely isolating the electrical components from hazardous paint fumes. All wiring utilized explosion-proof conduits.
3. Climate-Optimized Airflow & Heating
To combat the extreme UAE heat and ensure efficient curing, we configured a robust ventilation system delivering 40,000 m³/h of airflow via dual 7.5KW intake fans and an 11KW exhaust fan. For the baking phase, we integrated a high-performance Riello G20 Diesel Burner coupled with a 200KW 304 stainless steel heat exchanger, capable of raising the cabin temperature to 60°C in just 10-15 minutes, optimizing energy consumption against the local 380V/50Hz/3-Phase power supply.
4. Cost-Effective Installation Strategy
Rather than inflating the project cost with a turnkey overseas installation, CoatTech provided highly detailed 3D civil engineering and foundation drawings. This allowed the client to utilize their own local contractors to construct the dual-pit floor (760 × 6900 mm) equipped with 500kg/m² heavy-duty gratings, significantly reducing overall project expenses.
Key Technical Deliverables
Internal Dimensions: 8m (L) × 5m (W) × 4.5m (H)
Lighting: Top & Side mounted IP65 explosion-proof boxes (Total 80 tubes, ≥ 1000 LUX)
Filtration: 4-Stage Eco-filtration including Active Carbon Granular Filter for VOC absorption.
Heating: Riello Diesel Burner (Heats 20°C to 60°C in 10-15 mins).
Control: Centralized panel with automated pneumatic/electric damper controls.
Are you planning a similar industrial coating facility? Whether you are in the Middle East, Europe, or beyond, our engineering team can design a customized spray booth tailored to your exact dimensions, local power standards, and environmental requirements.
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