Case Study: Construction Equipment Coating Workshop
Summary
A large-part liquid coating workshop for a supplier of excavator booms and loader chassis to a major construction-machinery OEM in Russia, built around a 12 × 6 × 5 m spray booth with 60,000 m³/h filtered air supply and a matching 12 × 6 × 5 m forced-hot-air drying booth. Parts up to 10 × 4 × 4 m and 8 tonnes receive an epoxy primer, epoxy intermediate and polyurethane topcoat, and the coating reached 2,400 hours in salt spray against a 2,000-hour OEM target. Capacity is 200 large structural parts per month. Test results as reported at OEM coating certification in 2023.
Project Background
The client is a key supplier to a major construction machinery OEM in Russia, producing excavator booms and loader chassis. Their existing coating facility was outdated and could not meet the OEM's new coating durability requirements.
The Challenge
Construction machinery components weigh 3-8 tons and reach 12 m long — beyond the capacity of standard coating equipment. Outdoor working environments are severe, demanding heavy-duty anti-corrosion coatings that pass 2,000-hour salt spray.
MUSI's Solution
MUSI engineered a custom large-scale automatic spray booth: 12×6×5 m standard booth, with drive-through doors for forklift access, three-stage filtration + 60,000 m³/h forced air supply, paired with primer-intermediate-topcoat triple-layer heavy-duty anti-corrosion system.
Equipment Configuration
| Booth size | 12×6×5 m (L×W×H) |
|---|---|
| Max workpiece | 12×4×4 m, weight ≤8 tons |
| Air supply | 60,000 m³/h |
| Filtration | Pre-filter G4 + medium F7 + ceiling F9 |
| Coating system | Epoxy primer + epoxy intermediate + polyurethane topcoat |
| Drying booth | 12×6×5 m forced hot air |
| Environmental | Activated carbon adsorption + catalytic combustion |
| Monthly capacity | 200 large structural parts |
Equipment used on this line
- Automatic spray coating lines — overhead chain, floor belt and robotic flexible lines
- Liquid spray lines — water-based, solvent-based, electrostatic and 2K mixing systems
- VOCs and environmental equipment — RTO, RCO, activated carbon, zeolite rotor and wastewater treatment
Implementation
110-day project including foundation civil works + steel structure + equipment install + commissioning. Modular pre-fabrication + on-site assembly approach shortened schedule.
Results
Coating salt spray reached 2,400 hours (target 2,000 h), passing OEM coating certification. The client secured stable orders from major Russian and CIS construction equipment OEMs, with annual revenue exceeding $17 M USD.
Client Feedback
"Construction machinery coating standards keep getting tougher every year. MUSI helped us reach the highest OEM standard in one step — our biggest gain."
— Project Manager, Client Side
Selection logic: why this configuration
A drive-through booth with forklift access was chosen over a conveyorised line because parts of 3–8 tonnes and up to 12 m are moved more safely on transport frames than on hangers, and monthly volume of 200 parts does not justify a conveyor. Three-stage filtration (G4, F7, F9) was specified because a topcoat on a boom is inspected by the OEM for inclusions. Activated carbon with catalytic combustion was preferred to an RTO because the booth runs intermittently.
Scope of supply and key components
| Item | Specification | Notes |
|---|---|---|
| Spray booth | 12 × 6 × 5 m, drive-through doors | Parts to 10 × 4 × 4 m, 8 t |
| Air supply | 60,000 m³/h, G4 + F7 + F9 filtration | |
| Drying booth | 12 × 6 × 5 m forced hot air | |
| Coating system | Epoxy primer, epoxy intermediate, polyurethane topcoat | Paint supplied by the client |
| VOC treatment | Activated carbon adsorption + catalytic combustion | |
| Civil and steel | Foundations and steel structure | Included in this project as turnkey |
Key components
Key components are available from international brands, configurable per customer specification, so that spare parts can be sourced locally over the life of the line. Brand names below are the usual options for this type of equipment; the brands actually fitted are fixed in the contract specification.
| Component | Brands available on request |
|---|---|
| Automatic liquid guns, pumps and 2K proportioners | International tier-one spray gun, pump and 2K proportioner brands |
| Booth ceiling and intake filter media | Freudenberg Viledon, AAF SureStop, Camfil, MANN+HUMMEL |
| Oven and dryer gas burners | Riello RS series, Weishaupt monarch WM-G, Baltur TBG, Honeywell Maxon OVENPAK, Eclipse |
| PLC and HMI | Siemens SIMATIC S7-1500, Mitsubishi Electric MELSEC iQ-R, Schneider Electric Modicon, OMRON NX, Rockwell Automation Allen-Bradley |
| Variable-frequency drives | ABB ACS580, Siemens SINAMICS G120, Danfoss VLT, Schneider Electric Altivar, Yaskawa, Mitsubishi Electric |
| RTO ceramic media and burners | Lantec MLM, Honeywell Maxon line burners, Riello RS, Eclipse |
| Sensors and temperature controllers | SICK, Pepperl+Fuchs, OMRON E5CC, Honeywell UDC, Yokogawa UT, ifm, KEYENCE |
| Compressed air for powder feed and instruments | Atlas Copco GA, Ingersoll Rand RS, KAESER ASD, Sullair |
Not included in the scope of supply
- Building services up to the battery limit: power supply, gas, compressed air, water and drainage
- Local permits, emission approvals and third-party inspections
- Paint or powder supply, unless stated in the contract
- Paint and thinner supply
Services included with every line: engineering design, manufacturing, shipping documentation, installation supervision, commissioning, operator training, warranty and spare parts.
Typical programme
The durations below are typical for equipment of this class and are given for planning; they are not the recorded schedule of this project. A complete line usually runs 90–180 days from contract to acceptance, a single unit 30–60 days.
| Stage | Typical duration | What happens |
|---|---|---|
| Site survey and workpiece review | 5–10 days | Remote review of drawings and photos, or an engineer visit |
| Layout and detail design | 15–30 days | Layout drawing, utilities list and specification sign-off |
| Manufacturing | 45–90 days | Booths, ovens, conveyor, pretreatment and controls built and pre-assembled at the works |
| Shipping | 20–45 days | Sea freight; equipment shipped in sections for on-site assembly |
| Installation | 15–40 days | MUSI supervision with the client's installation crew or MUSI crew |
| Commissioning, training and acceptance | 7–15 days | Trial runs on the client's parts, operator training, acceptance record |
Results: before and after
Figures are those published on this page; measurement party, sample size, test date and method are not on record here and are left blank rather than estimated.
| Metric | Before | After | Change | Measured by | Single / average | Samples | Test date | Method / instrument |
|---|---|---|---|---|---|---|---|---|
| Neutral salt spray | 2,000 h OEM target | 2,400 h | +400 h over target |
Applicability and limits
The 2,400-hour salt-spray result applies to blast-cleaned steel with the three-coat epoxy-polyurethane system applied in a controlled booth. Plants that skip blast cleaning or apply a single coat will not reach the same figure, and the booth size given here is sized for booms and chassis rather than complete machines.
Results shown in this case study reflect the stated operating conditions and should not be interpreted as guaranteed performance under different feed, production, environmental, or site conditions.
After-sales and spare parts
Warranty on a MUSI coating line runs from acceptance: 12 months on the complete line excluding consumables, 36 months on critical components such as motors, drives and the PLC, and 60 months on structural parts such as steel structure, ducting and oven bodies. Failures within warranty, excluding misuse, are repaired free of charge.
Support starts remotely: the service line is staffed around the clock, a preliminary diagnosis with recommendations is given within 2 hours, and where a site visit is needed an engineer reaches any major city within 72 hours. A spare-parts inventory is held at the Changzhou headquarters with same-day shipping, and customers can keep a dedicated parts stock at MUSI for emergencies. Details are on the after-sales service page.
FAQ
How big a part can a spray booth like this take? Parts up to 10 × 4 × 4 m and 8 tonnes in this 12 × 6 × 5 m booth, moved in on transport frames by forklift through the drive-through doors.
Why three filter stages on the air supply? A G4 pre-filter protects the F7 stage, and the F9 ceiling filter keeps particles out of the topcoat, which the OEM inspects for inclusions on visible faces.
Is a conveyor needed for heavy machinery parts? Not at 200 parts a month. Below roughly 30 parts a day a batch booth with forklift or transfer-cart handling is simpler and safer than hanging 8-tonne parts.
What coating system reaches 2,000 hours salt spray? On this project, epoxy primer, epoxy intermediate and polyurethane topcoat over blast-cleaned steel; it tested at 2,400 hours.
Was civil work part of the delivery? Yes, this project included foundations, steel structure, equipment and commissioning in a 110-day programme using modular prefabrication and on-site assembly.
Next step: a configuration proposal for a similar line
If your parts, volumes or plant conditions are close to this project, MUSI can return a line configuration and layout proposal. To prepare it we need four things:
- Photos and dimensions of the workpieces, with weight and material
- Required output (pieces per hour or per day, and shifts)
- Number of colours and how often colour changes are needed
- Available floor space and ceiling height, with the utilities on site
Message us on WhatsApp with these details, or use the quotation form.
Provided by Lin Cong, Technical Director, MUSI Technology · Published 2026-05-02 · Updated 2026-09-30 · Last technical review: 2026-09-30
QQuestions buyers ask before ordering
quotation · price · lead time · installation · warranty
What information do you need to prepare a quotation?
Send part drawings or photos, the largest part size and weight, the material, the required output per shift, the paint or powder type and number of colours, and the available floor space, ceiling height and power or gas supply. MUSI engineers reply within 24 hours; a recommended configuration and quotation follow once your part data is complete.
How much does this equipment cost?
Budget depends on part size, throughput and the level of automation. Indicative ex-works ranges are published in our complete coating line cost guide; a configured quotation is prepared from your part data. Published indicative ex-works ranges: a complete powder coating line is roughly USD 75,000–230,000 semi-automatic, USD 200,000–600,000 for a standard automatic line and USD 600,000–2,000,000 for a high-throughput automated plant.
What is the lead time?
Standard configurations ship in 30–60 days from contract signing and down payment; custom configurations take longer. The delivery date is fixed in the contract.
Do you install and train operators overseas?
Yes. MUSI engineers carry out on-site installation and commissioning and give 3–5 days of operator and maintenance training. MUSI has delivered 800+ coating lines to customers in 36 countries.
What warranty and after-sales support are included?
12 months full-machine warranty, 36 months on critical components and up to 60 months on structural parts. International customers get 24-hour phone response and 72-hour on-site arrival; spare parts ship from the Changzhou headquarters.
Can the environmental equipment be supplied with the line?
Yes. VOC treatment (RTO, RCO, activated carbon, zeolite rotor), dust collection and paint wastewater treatment are supplied with the coating line under one contract; MUSI has equipped 50+ coating facilities whose projects all passed local environmental compliance reviews.
Get a Similar Solution
If your industry and requirements match this case, contact MUSI to schedule a free consultation. We'll design an optimal solution based on your specific workpieces, capacity, and facility.