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radiator, dipped in primer, production Zehnder Charleston, Lahr, electrolytic primer coat bath, dip coating
Decorative Radiators

Manufacturing the Multi-column

The Zehnder Charleston radiator has played a key part in the company’s success for nearly 100 years. Continuous advances in the quality of production methods and technology has kept the Charleston Multi-column at the forefront of the radiator market. Take a look behind the scenes to discover how they are made.

Take a look behind the scenes to discover how the famous Zehnder Charleston Multi-column is made...

Step 1
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Step 5
Step 6
Step 1

Preparation of raw materials

During the first phase of production of a multi-column radiator, steel strips are wound into a coil measuring 1200mm to 1500mm in diameter and weighing over 2 tonnes.  Steel tubes measuring 4 to 6 metres are used to create the radiator columns.

Step 2

Production of the collector

The coils of steel are punched by a press to create the two halves of the collector.  The two pieces are then welded together to form double-machined heads.  These headers are then sanded and cut in half to create two collectors.  These elements are then quality checked before moving onto the next stage. 

Charleston, new technology, half shell, half shells , 3-column, production
Charleston, new technology, half shell, half shells , stamping, 3-column, production
Step 3

Production of the section

The collectors and the tubes are now welded together and then ground to make neat joins.  At each stage the sections are checked and quality controlled.

The sections are hermetically sealed and then immersed in a bath of water.  Each section is then subjected to a pressure of 16 bar to check for leaks.

Step 4

Assembly

The radiator sections are now connected to each other using tip-welding.  Further testing then checks each radiator for leaks.

After testing, the radiator is suspended ready for the next stage in production.

Step 5

The finishing touches

Radiators are initially cleaned to remove dust and grease before an electrophoretic base coat is applied for corrosion protection and a flawless foundation. The radiator then undergoes baking in a furnace at roughly 180°C to affix the primer to the steel.

Upon cooling, the radiator advances along the production line for powder coating, a more eco-friendly process than traditional wet painting. While standard white radiators receive automated painting, other colours and finishes are manually sprayed. The radiator then re-enters the oven, where the powder melts uniformly to provide a shock and heat-resistant finish of superior quality.

Step 6

Quality control and packing

Before packing, each radiator is thoroughly quality checked once again and then up to 98% of radiators are packaged and wrapped using a fully automated system.

Step 1

Preparation of raw materials

During the first phase of production of a multi-column radiator, steel strips are wound into a coil measuring 1200mm to 1500mm in diameter and weighing over 2 tonnes.  Steel tubes measuring 4 to 6 metres are used to create the radiator columns.

Step 2

Production of the collector

The coils of steel are punched by a press to create the two halves of the collector.  The two pieces are then welded together to form double-machined heads.  These headers are then sanded and cut in half to create two collectors.  These elements are then quality checked before moving onto the next stage. 

Charleston, new technology, half shell, half shells , 3-column, production
Charleston, new technology, half shell, half shells , stamping, 3-column, production
Step 3

Production of the section

The collectors and the tubes are now welded together and then ground to make neat joins.  At each stage the sections are checked and quality controlled.

The sections are hermetically sealed and then immersed in a bath of water.  Each section is then subjected to a pressure of 16 bar to check for leaks.

Step 4

Assembly

The radiator sections are now connected to each other using tip-welding.  Further testing then checks each radiator for leaks.

After testing, the radiator is suspended ready for the next stage in production.

Step 5

The finishing touches

Radiators are initially cleaned to remove dust and grease before an electrophoretic base coat is applied for corrosion protection and a flawless foundation. The radiator then undergoes baking in a furnace at roughly 180°C to affix the primer to the steel.

Upon cooling, the radiator advances along the production line for powder coating, a more eco-friendly process than traditional wet painting. While standard white radiators receive automated painting, other colours and finishes are manually sprayed. The radiator then re-enters the oven, where the powder melts uniformly to provide a shock and heat-resistant finish of superior quality.

Step 6

Quality control and packing

Before packing, each radiator is thoroughly quality checked once again and then up to 98% of radiators are packaged and wrapped using a fully automated system.

High-tech, residue-free welding method

Zehnder Charleston LaZer made

The fact that Zehnder Charleston has become a radiator classic is down in no small part to its innovative strength. And even today it boasts a unique features: the manufacturing of Zehnder Charleston with LaZer made. This innovative laser welding method for the production of sectional radiators is setting new standards for quality and technology in terms of precision, quality and functionality.

Unique Industrial Finish

Zehnder Charleston in Technoline

Zehnder Charleston in Technoline adds a touch of industrial flair to your space with its raw and authentic finish. This distinctive style embraces the manufacturing marks, inconsistencies and irregularities that occur during the production process, making each radiator a unique piece. The resultant variations in tone and pattern depend on the dimensions of the radiator and the techniques used during fabrication.

Clay kiln factory, Lahr town museum, museum of local history, Germany, renovation, 2018, exhibition room of the museum, reference
Zehnder Charleston in Technoline

When considering the Zehnder Charleston in Technoline, it is helpful to note that models in Technoline equal to or over 400mm in height (excluding feet) typically presents a uniform, light top. The Zehnder Charleston models in Technoline which are under 400mm in height (excluding feet) bear darker welding marks near the top and bottom, accentuating their industrial character.

Please note: This finish is not suitable for bathrooms.

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