Transport

Metalspraying equipment and materials are extensively used in all areas of Road, Rail, Sea and Air transport to reclaim and salvage over – machined or worn parts, to provide friction and wear control on new parts and to prevent corrosion.

Sea

Corrosion is a major problem for the shipbuilding and fishing industries.

To ensure the long-term anti-corrosion protection of the ocean going vessels, metal spray is used on various parts of the vessels with an aluminium and zinc coating.  Many parts of the vessels are specified to be metal sprayed for improved safety, durability and hence life cycle costs.  Metal spray is much more durable than paint and independent European standards (EN14713 and EN2063) show that a life to first maintenance of 20 years or more can be achieved in sea water splash zones.  The deck and the hull, which sits above the waterline, have to be metallised to protect them against the harsh sea environment.

 

Other parts of the vessels metal sprayed includes, the Refrigerated Sea Water (RSW) tanks, where fresh fish are stored on board, fish processing rooms, chutes into the fresh fish tanks, net winching sheaves and drums, masts and the trawl boards.  Not only are these elements exposed to the harsh, destructive sea environment, but also to the daily ravages of wear and tear of the equipment used in the trawling process.  The durability of metal sprayed coatings means that maintenance downtime to re-paint these areas is greatly reduced.

Transport

Metal or thermal spraying is a technology that protects or extends the life of a wide variety of products in the most hostile environments and in situations where coatings are vital for safety and performance.

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Durable non-slip coatings can be applied for use on steel floors, ship decks and panels across diverse industries, from train steps and manhole covers to oil platforms and ships

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Spraying the stern of a crane with Zinc using Arcspray

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Other areas where Metalsprayed anti- corrosive coatings are applied include Radar Masts, Steam pipes, Exhaust pipes, Ladders, Lifeline Stanchions, Diesel Exhaust Stacks, Steam riser Valves etc.

The reclamation of worn parts for ships is usually subject to Lloyds Registry particularly on

larger vessels. Applications include the reclamation of Propeller Shaft Bearing Journals, Turbo Hydraulic Pump, Rudder, Bilge Pump, Main Circuit Pump, Stabiliser, Capstan, Winches etc.

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 Ships White Metal Bearing

This White Metal Bearing was flame metalsprayed in Australia during June 2005. The bearing has a diameter of 450mm and a length of 350mm. The bearing is from the P&O Cruise Liner- Pacific Sky. The Pacific Sky caters for 1550 passengers on 11 decks and is 240m long. The ship was built in 1984 weighs 46,000 tonnes and has a top speed of 21 knots.

Rivers and Canals

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Arcsprayed Zinc (TSZ) onto a Narrow Boat to stop corrosion

 

Road

Please refer also to the Automotive section.

The problem of corrosion on road vehicles is receiving ever-increasing attention and various systems are being devised to protect private cars. For commercial vehicles however, such as a semi-trailer, without doubt, the best means of protection for the long life expected from these units is zinc spraying which will fully protect against rust and corrosion for a minimum of ten years without maintenance.

The specification for the treatment of chassis was gritblast followed by 100 microns (0.004”) zinc sprayed with an Arc or Flamespray system. The manufacturer’s usual decorative paint finish was then applied. Chassis treated in this way have been running for a number of years and the treatment has proved entirely satisfactory.

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An Anti- slip coating can also be added to improve safety in wet conditions; this has also been carried out on the Tail lift of vehicles.

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The external framework of Reefer refrigeration containers have been automatically  coated with an Arcsprayed Anti Corrosive coating to protect against  corrosion and damage caused by loading and unloading from vehicles and ships as the Metalspray is more durable than just paint.

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Air

Please refer also to the Aerospace section also.

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With increased air travel and a diverse range of commercial passenger jets landing at New Zealand airports, robust, attractive air bridges are a necessity. The air bridges also need to be versatile and able to accommodate current and new generation commercial jets, particularly the new Airbus A380.

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Typically, Pacific Rim airports are often located on the coast and air bridges are exposed to this harsh marine environment. Coating systems have to provide long-term, advanced corrosion protection and be visually attractive to the same high standard as automotive bodywork. This requires a zinc anti-corrosion coating that is smooth enough to facilitate a functional, yet decorative, paint system and protect the air bridge against the elements.

 

Metalspray coating for Animal transport vehicles

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.

 

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