The Metalspray process has many applications that are carried out Worldwide. One of its major applications is the application of anti –corrosion coatings. The material applied maybe Zinc (as used in the Galvanising process), Aluminium or alloys of these materials.

The application of the coating is generally by Arcspray (sometimes referred to as twin wire arc spray) is a process that uses an electric arc to melt wires.  The molten metal is then atomised with compressed air to create a spray stream that applies the coating onto the surface being sprayed.

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As well as providing anti –corrosion protection the coating can be applied with a coarse coating to provide anti-slip properties particularly useful on vehicle tail lifts and ramps on commercial vehicles and trailers.

An application where the Metalspray process has a significant advantage over Paint and Galvanising is in Animal transport vehicles and trailers. Not only does the surface have to be able to withstand wear from the animal hooves etc. that may contain erosive soil but also the chemical effect of their urine and excrement. The use of Zinc in this application works within a pH range of 6 to 10. The urinary pH range for the cow, sheep, goat, and horse is ∼7.9 ± 0.5. For the pig, this range may extend to 6.5 ± 1.5, for cats and dogs 6.0 ± 1.0, and for humans 6.5 ± 1.5 (1). The diet of the animal is the major determinant of urinary pH levels.

How does Metalspray compare with Painting?

  • Materials are of consistent quality and purity, no mixing required before application
  • Materials have an infinite shelf life if stored correctly
  • Fewer process steps required. This allows simpler quality control and fewer opportunities for error.
  • Sprayed components require no protracted curing or drying times giving superior utilisation to floor space
  • Sprayed Zinc, Aluminium and their Alloys give effective corrosion resistance and protection immediately
  • Sprayed metals are more robust than paints and can withstand rougher usage
  • Even if the sprayed layer is damaged the sacrificial action prevents corrosion.
  • Metals can be sprayed in a wider range of climatic conditions (temperature and humidity) than paints
  • The materials used since the early 1900’s have not changed they are still in existence today, whereas many paint systems have been superseded many times over.

How does Metalspray compare with Galvanising?

  • Low heat input during spraying eliminates the risk of component distortion
  • There is no limit to the size of component to be treated
  • Components can be treated on site and therefore no transport or waiting issues and giving you the opportunity to Up Sell to your customer.
  • Metalspraying is used to restore corrosion protection on damaged areas of welded galvanised steel and International Standards exist covering this
  • Coating thickness can be varied from area to area to provide extra protection in critical areas
  • The Metalspray process is not limited to Zinc as Aluminium, Steels, Bronzes etc. can also be applied for a variety of applications
  • No re-work required from Galvanising dross
  • The Metalspray coating is porous and therefore the perfect surface to accept paint (that’s if required as it is not necessary). No need to pre –etch etc.
  • “AS/NZS 2312 Guide to the protection of iron and steel against exterior atmospheric corrosion” is the Australian Standard based on the International ISO standard that provides guidance for architects, engineers, builders the surface coating industry and users of protective services in general, on coating system for the protection of iron and steel against exterior atmospheric corrosion.

As indicated above the Metalsprayed coating is porous and therefore in this application the use of a  paint sealer would be required, which as shown in AS/NZS 2312 would further enhance the lifecycle of the coating.