TUFFSPAN® ROOFING PANELS WITHSTAND ACIDIC GALVANIZING CHEMICALS

Operating for over 50 years, a large plant in the Southern U.S. galvanizes large quantities of metal each day, a process reliant on highly corrosive chemicals like hydrochloric acid (HCl).

Before it can be dipped in molten zinc to be galvanized, the metal enters the HCl to be cleaned of impurities. The metal “agitates” the acid, releasing HCl fumes. This acidic mist is highly corrosive to metallic surfaces. The molecular reaction between HCl and metal caused some roofing panels to rust in just a few years, requiring the company to incur frequent replacements. Unsurprisingly, it was especially frequent for roofing panels immediately above the acid-handling areas of the facility floor.

In addition to experiencing multiple roof repairs and area replacements in under two decades, the facility had another side effect of a metal roof: it was very, very dark inside. Unlike homes or office buildings that brighten a space with windows, a galvanizing facility needs the strength of solid walls. This meant the galvanizing facility relied entirely on artificial light.

In 2003, the galvanizing company contracted a small, partial replacement for some of its roofing panels from a nearby manufacturer of Fiber Reinforced Polymer (FRP) composite roofing panels. That company was Enduro Composites, part of Creative Composites Group (CCG).

The metal treatment company had conducted their own proof-of-concept testing in 2003, and so in 2025, they knew they wanted an entire roof made of TuffSpan panels.

TuffSpan proved ideal for their galvanizing facility. FRP is inherently corrosion-resistant and will not rust when exposed to HCl fumes. It is also lighter weight than metal and will not grow as hot to the touch when exposed to sunlight, which benefits installation teams. And like all CCG products, TuffSpan is Made in the USA, meets BABA and is completely traceable to our U.S. facilities.

A 163,000-square-foot TuffSpan roof now tops the facility in Texas. The facility now enjoys 40% light transmittance from its TuffSpan panels, bringing natural light into the facility without compromise to panel strength.

Installation caused zero business interruptions. Because CCG’s Enduro facility is 20 minutes from the metal treatment plant, the customer saved inestimable shipping costs while enjoying a batch-style delivery, in lieu of the entire order left sitting in a loading yard for months.

The galvanizing company has been so impressed with the results and the positive impact of these TuffSpan panels that they're evaluating the possible benefits of FRP for other areas of their business.

See how a rendering facility excels with Enduro’s TuffSpan roof and wall panels and the difference FRP flanged tube beams made for a galvanizer’s HCl storage tanks.