April 22, 2026
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Earth Day is not just a once-a-year moment at The IRON Shop. It is something built into how we design, manufacture, and finish every product that leaves our facility. When you are working with metal, coatings, and fabrication, every step has an impact. That means every decision matters.
From the materials we choose to the way we manage water and waste, sustainability is not an afterthought. It is part of the process.
To give a real look behind the scenes, we spoke with our Finishing and Coatings Manager, Alyssa, who leads the team responsible for delivering the high-quality finishes you see on our Spiral Staircases and other custom metal products.
Meet the Expert Behind the Finish
Alyssa’s background in metalwork started early. Growing up around Detroit’s automotive industry, she was surrounded by fabrication and began welding at just 16. After gaining experience in both industrial fabrication and the art world, she brought that mix of creativity and technical skill to The IRON Shop.
She started as a patina artist, moved into quality control, and now leads the finishing and coatings department. Despite her leadership role, she still prefers to stay hands-on.
In finishing, even small variables like temperature and humidity can affect results. Precision matters, especially when products are on tight deadlines and expected to meet the highest quality standards.
Why Powder Coating Matters
If you have ever opened a can of traditional paint, you have likely noticed the strong smell. That comes from VOCs, or volatile organic compounds, which release into the air during application.
Powder coating offers a cleaner, more efficient alternative.
At The IRON Shop, approximately 80 percent of our products are finished using powder coating. This process:
For projects like Outdoor Spiral Staircases, where exposure to the elements is constant, powder coating provides both environmental and performance benefits.
When wet paint is required, we prioritize low-VOC, LEED-certified options whenever possible.
How the Powder Coating Process Works
Powder coating is not just a simple spray application. It is a detailed, multi-step process designed for durability and consistency.
Parts are first organized and placed on a trolley system before entering a five-stage pretreatment washer. Unlike traditional linear systems, our batch washer completes the full cleaning process in one location.
During pretreatment, the metal is cleaned, etched, and sealed with a zirconium conversion coating. This creates a protective layer that prepares the surface for coating.
After drying, automated spray guns apply the powder using an electrostatic charge. The powder adheres to the surface and is then cured in an oven, creating a smooth and durable finish.
Within a few hours, the product is fully coated, cured, and ready to move forward. This efficient process supports both quality and sustainability.
Built to Last Means Built Sustainably
One of the most important aspects of sustainability is longevity.
The finishes used on our products meet AAMA 2605 standards, which is the highest level of performance for coatings on architectural aluminum. This means10 years minimum protection against weather, humidity, and saltwater corrosion resistance using fluoropolymer technology, and 15-30 years of life with a fluoropolymer coating.
This level of durability delivers long-term benefits:
For customers investing in Custom Spiral Staircases, durability is not just a feature. It is a long-term environmental benefit.
Water, Waste, and Responsible Practices
Metal finishing does not stop at what you see on the surface. It also involves managing what comes off during the process.
During pretreatment, oils, debris, and contaminants are removed from the metal. That wastewater is carefully handled through:
We work closely with local authorities to ensure all wastewater meets strict environmental standards. This ensures that our operations support both quality manufacturing and environmental responsibility.
Safety Is Part of Sustainability
A responsible process also means protecting the people behind the work.
Our team uses appropriate protective equipment depending on the task, including:
Every step is guided by safety protocols and ongoing training to maintain a safe and consistent work environment.
Always Improving
Sustainability is not static. There is always room to improve.
One idea currently being explored is reusing leftover powder coatings by blending them into an upcycled primer. While the final color may not be traditional, it could reduce material waste and lower overall consumption.
Innovations like this continue to push the boundaries of what sustainable manufacturing can look like.
Why Earth Day Still Matters
For Alyssa and the team, Earth Day is personal.
The choices made in a manufacturing environment have a direct impact, but so do the small decisions made at home. Whether it is finishing a product in a facility or painting something in your backyard, every action contributes to a larger outcome.
The Bottom Line
At The IRON Shop, a great finish is about more than appearance. It is about how the product is made, how long it lasts, and how responsibly it is produced.
From powder coating to water management to ongoing innovation, sustainability is part of every step. That is how we continue to deliver high-quality products while doing things the right way for our customers, our team, and the environment.
A special thank you to Alyssa for sharing her expertise and giving us a behind-the-scenes look at the finishing and coatings process. We appreciate everything she and her team do every day.
