COATING GUIDE

In this section you will find helpful information relating to anti corrosion
coatings for long term protection of steel structures. This is to be concidered
as a guide only as many aspects have been omitted in order to keep it
brief. Specifiers and Contractors should always refer to the
relevant Standards for more detail or contact us for our assistance.
Recent surveys showed 80% of coating failures were due to incorrect or
inappropriate specification with the balance due to incorrect application.

COATING SELECTION
This section provides guidance on the use of different types of metallic coating systems for the protection of steel
structures against atmospheric corrosion.
Firstly, we need to determine the coatings durability or otherwise called "lifetime to first major maintenance". The
following five ranges are commonly used:

 Short term = 2 to 5 years

 Medium term = 5 to 10 years
 Long term = 10 to 15 years
 Very long term = 15 to 25 years
 Extra long term = 25+ years
 40+ years possible.

Secondly, we need to determine the environment at which the structure is to be located and the atmospheric
corrosivity at this location. Atmospheric environments are classified into the five following categories:

 Category A (Very low) = Internal areas with dry atmosphere remote from marine or industrial influence.
 Category B (Low) = Rural inland, low polution.
 Category C (Medium) = Urban inland or mild coastal.
 Category D (High) = Industrial inland, urban coastal.
 Category E (Very high) = (E-I Industrial) Industrial with high humidity, (E-M Marine) High salinity coastal. 
 Category F (Inland tropical).

NOTE: other micro climate influences need to be considered such as shaded or wet areas, geothermal emissions,
humidity, prevailing winds or steel in contact with concrete.
 
With the required lifetime to first maintenance and atmosheric corrosivity details we reference zinc corrosion rates
in each of the environment categories according to ISO 9223. The life of a metal sprayed coating is directly
proportional to the thickness applied per area, usually micron (µm) per square metre (m2). The greater the thickness
of a metallic coating, the greater is the expected life of the coating.

Guidance on years of service to first major maintenance to be expected for metal sprayed coatings for different
environmental conditions are provided in the table below:
S = Sealed.
* = Would have very high durability but would be uneconomical.
NR = Not Recommended.

Coating.
TSZ = Thermal Sprayed Zinc. Recommended for pH 5 - 12. Weight of wire required 1.2kg/m2/100µm.
* Excellent protection against atmospheric corrosion.
* High so called “cathodic (long distance protective) reaction".
* Life cycle time proportional to coating thickness.
* Inadequate in the case of higher salt content in air, as for coastal regions.
* Corrosion behavior similar to that of hot dip galvanizing.
 
TSA = Thermal Sprayed Aluminium. High temperature, seawater immersion and marine splash zones.
Recommended for pH 4 - 9. Weight of wire required 0.35kg/m2/100µm.
* Especially sufficient for SO2 containing industrial atmosphere.
* Well sufficient for marine atmosphere and in seawater.
* High heat resistance.
* Highly resistant against acidic contamination.
* Low cathodic long distance protective reaction in the atmosphere.
* Cathodic long distance protective reaction high in a strong electrolyte only, e. g. sea water.
 
NOTE: 85/15 alloy (85% zinc, 15% aluminium) provides twice the protection of zinc. Weight
required 1.0kg/m2/100µm.
* High corrosion resistance also in low acid medium.
* Higher corrosion resistance against atmospheric corrosion than zinc and aluminium.
 * Higher corrosion resistance against chlorides and especially SO2 containing atmospheres than zinc.
* Inadequate for applying in salt water without organic coating.
 * Cathodic long distance long distance reaction, however smaller than for pure zinc.
 

PREPARATION
For new steel, all surface imperfections such as sharp edges, weld splatter, weld folding and slag shall have been
removed from surfaces. All edges shall have a radius of curvature of no less than 2.0mm.
ABRASIVE BLASTING
Grit blasting is the only method of preparing surfaces for metal spraying. It removes rust, mill scale and other surface
contaminants and produces a suitably roughened surface profile. Clean, dry, compressed air shall be used for
blasting. Moisture separators, oil separators, traps or other equipment may be necessary to achieve this requirement.
A high standard of surface preparation is required to develop the optimum thermo-mechanical bond required for
metal sprayed coatings. Steel surfaces to be arc sprayed with zinc or aluminium or to be flame sprayed with zinc
should be abrasive blast cleaned to at least Class 2.5 to produce a sharp angular profile of at least 50µm. Steel
surfaces to be flame sprayed with aluminium or aluminium alloys should be abrasive blast cleaned to Class 3 to
produce a sharp angular profile of at least 75µm. Profile depth should be measured using a surface profile gauge or
replica tape. Coating thicknesses in excess of 300µm may require an increase in surface profile. 
Metal sprayed coatings should not be applied if any discoloration of the cleaned surface has occurred, or when the
temperature of the substrate is below the dew point. Any visible rust that forms on the surface of the steel after blast
cleaning shall be removed by re-blasting the rusted areas to meet the requirements of the specification before metal
spraying.

SPRAYING
The first metal spray coat should be applied within 4 hours after the last cleaning and before any discoloration of the
prepared surface occurs. Spray angle should be near to right angles to the substrate as possible, with a spray range
or standoff between 100 - 200mm. The sprayed metal coating should overlap on each pass. Two or more coats of
this layer should be sprayed alternatively in vertical and horizontal passes to ensure uniform coverage to the
minimum specified coating thickness.

SEALING
Due to the thermal spray process, the coating typically has around 10% porosity. The purpose of sealing is to fill this
porosity and delay oxidization of the coating . Sealing extends the life of the coating as well as providing a smooth
finish and giving color if desired. Ensure the coating is free of moisture before application and all solvents have
evaporated before subsequent coats to avoid solvent entrapment.

PAINT SYSTEMS
Metal sprayed anti corrosion coatings are normally put into service without any finishing, however sealers and paint
systems can be applied to suit particular environmental conditions or if aesthetics require.
When steel protected only by paint is damaged or weathered, it can corrode in the unprotected area and additionally
proceed to corrode the steel under the paint, a phenomenon called “scribe creep”. The corrosion products of iron
are many times higher than zinc, resulting in progressive failure or paint peeling away from the damaged or
weathered site. By contrast, when the steel is protected by TSZ that is then painted, any damage to the paint, even if
it goes through the TSZ, does not result in significant steel attack. The TSZ coating galvanically protects the steel
until it is consumed, minimizing scribe creep failure of the paint and also greatly reducing the severity of steel
corrosion.  150 - 200 micron TSZ alone can provide up to 25+ years to first maintenance in most environments.
Should the steelwork require a paint system for aesthetic reasons, it is not always necessary to retain the same 150-
200 micron of the TSZ as it is there to galvanically protect the steel with the paint acting as a barrier. An example
specified widely overseas: 100 micron TSZ, 50 micron epoxy sealer, 100 micron epoxy build coat, and 50 to 100
micron polyurethane. 
TSZ applied by arc spray equipment achieving high production rates, poor machine settings, rough finishes or higher
coating thicknesses may produce a coarse surface profile of the finished coating. This may be an issue in some
cases when TSZ is to be part of a duplex system. A specification of a low build paint system or areas of low paint
build during application may cause ‘peaks’ in the TSZ to activate, causing white zinc oxide and blistering the barrier
coating. AS/NZS 2312 recommends a profile height of less than 50 microns for TSZ before paint system is applied.
TSZ coatings have a porosity of approx 10%, depending on the specification or desired finish a low viscosity material
with good wetting properties such as vinyl, acrylic, or thinned epoxy are used. Higher volume solids are preferable to
reduce the number of sealing coats required. Be sure all solvents have evaporated before subsequent coats to avoid
solvent entrapment. Always discuss with your paint representative for the correct sealers/topcoats, application, drying
times and coating thicknesses for paint application over TSZ coatings.

ANTI CORROSION WIRE

MSS stock the largest range and volumes of arc spray and flame spray
wire for corrosion protection in diameters 1.6mm, 2.3mm, 3.17mm &
4.76mm in both MIG spools and bulk drums. We hold stock in our Grey
Lynn office and we also have Zinc wire in bulk drums available
from Auckland and Christchurch distribution warehouses for fast
deliveries to our customers.

Zinc Wire
Aluminium Wire
85/15 (85% Zinc, 15% Aluminium) Wire
ZINC WIRE
Most commonly used, Zinc provides galvanic protection sacrificing itself in preference to the steel. Corrosion
protection coatings of zinc are normally put into service without any finishing, however sealers and paint systems can
be applied to suit particular environmental conditions or if aethetics require. Traditionally used for long term corrosion
protection of iron and steelwork, zinc is now also used extensively in mould making, electro-magnetic screening and
for the end spraying of capacitors.
15kg MIG spools, 125KG Mini Drums, 250KG Bulk Drums.
Zinc -  Weight of wire required 1.2kg/m2/100um

ALUMINIUM WIRE
Aluminum acts as a passive barrier and is used to provide protective coatings against atmospheric, chemical
and high temperature corrosion. Aluminium is also used to produce electrically and thermally conductive coatings
and to reclaim mis-machined aluminium surfaces. Corrosion protection coatings of aluminium are normally put into
service without any finishing, however sealers can be applied to suit particular environmental conditions. In other
applications a variety of finishes can be achieved by machining with either steel or carbide tools, sanding, polishing or
burnishing.
6KG MIG spools, 60KG Bulk Drums.
Aluminium - Weight of wire required 0.35kg/m2/100um
85/15 ALLOY
85/15 (85% Zinc, 15% Aluminium) incorporates the best characteristics of both zinc and aluminium and is becoming
widely used offering twice the protection of pure zinc. In corrosion protection of iron and steel, the combination of zinc
and aluminium provides excellent cathodic protection in most environments. In mould manufacture this material being
harder than pure zinc gives better service life and improved thermal conductivity at the expense of some profile
definition. Can also be used for EMI Screening and End Spraying of Capacitors.
15KG MIG spools, 200KG Bulk Drums.
85/15 Alloy - Weight of wire required 1.0kg/m2/100um

ARC SPRAY
Arc spray or 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. Anti-corrosion or engineering coatings can be applied
by arc spray and changing between the two is quite simple.  Arc spray
systems are commonly considered to be easy to operate and also to
automate.

Heat Source: Electric arc

Material: Wire
Transfer: Compressed air
Process: Two wires are fed into the pistol and electrically charged, one positive and one negative. The wires are
forced together and form an electric arc, melting the wire. Compressed air, passing through a nozzle, atomises the
molten metal and sprays it onto the work piece. 
 ARC150/S500-CL

In response to feedback from customers for a flexible system but with higher throughput, Metallisation have created
the 500Amp, ARC150/S500-CL arc spray system. The ARC150 system offers a great balance of controllable
throughput with flexible operation and the opportunity to have extended supplies packages up to 50m from the
energiser to the pistol.
A number of new features are included to enable reliable spraying at 500A, 100% continuous duty cycle. These
include a new pistol front end with contact tips instead of solid tubes; uprated supplies / cooled conductors and
terminals; a heavy duty drive unit with new, v-shaped rollers; heavy duty flexible drive and a new 500A energiser with
high specification digital meters. These features combine to give a flexible, reliable and manageable solution for
medium and large scale thermal spray applications, producing quality, fine surface finish coatings.
The ARC150 system is designed for anti-corrosion applications spraying zinc, aluminium and their alloys but can
also be used to spray other materials commonly sprayed in larger applications such as high temperature alloys.
Key features

 500A capacity = high productivity

 Closed-loop current = simplicity / reliability
 Uses 2.3mm anti-corrosion wires
 1.6mm setup for high termperature alloys
 Air cooled cables = lightweight
 Flexible pistol manoeuvrability
 New 500A energiser with digital display
 10 and 20m supplies packages (max wire feed)
 Extension supplies to extend up to 50m
 Easy to setup and maintain = high productivity
 MIG, hardboard reel and drum dispense
 New heavy duty drive unit and rollers
 New contact tips = reliability at higher current
 100% duty cycle = reliability and productivity

ARC145/S245 & S345-CL

Metallisation's desire for continuous improvement, alongside customer feedback has led to the development of the
latest range of ARC145 systems. The systems combine the best elements of the proven ARC140 system and the
more recently released ARC150 system.

The ARC145 pistol utilises the latest in design of contact tips and air-concentrator. The head design, along with the
contact tips improves cooling to the arc area, resulting in longer contact tip life and more reliable operation when
spraying for extended periods of time. The improved airflow and more efficient arc also allow the system to produce
a finer coating without compromising deposit efficiency. The new tips, manufactured from a hard wearing, copper
alloy are quick and easy to change. The new material, along with improved cooling help to enhance tip life
considerably and reduce downtime and running costs.

The ARC145 pistol also includes other enhancements such as measuring the spray voltage at the pistol (assisting
diagnostics and simplifying setup) and more simple, robust push buttons. A small amount of weight is taken out of the
pistol compared to the ARC140 and a more robust control cable connection is also introduced. Reversible (twice the
life) V-rollers complete the ARC145 pistols new features and ensure the most reliable wire feed possible.

The reversible V-rollers also feature on the new ARC145 wire drive unit which utilises the proven technology from the
ARC150 spray systems. A larger motor, inverter and independent tension drive unit gives the very best in reliable
and repeatable wire feeding.

The new drive unit and pistol are still joined with Metallisation's patented ‘Synchrodrive’ principle. The flexible drive
cable in 5m, 10m, and 20m lengths, combined with the V-rollers and more positive drive unit ensure the ultimate
performance and reliability of wire feeding. The ARC145 system has been extensively tested with a range of coating
wires and proven to give excellent performance over 20m feed lengths with the most challenging, cored engineering
wires.

The energiser range includes the latest enhancements introduced to the range at the start of 2016. 

 The latest version of PLC is fitted ensuring long future proofing and support.
 Digital gauges offering both scale and numeric displays.
 MCB’s are fitted to the incoming power supply as additional protection if the correct fusing is not fitted to the
electrical supply.
 New Data Kit option giving the possibility of remote monitoring and logging of certain energiser data at a
customer’s HMI via a Siemens S7-1200 series CPU.

The system is designed for demanding engineering and anti-corrosion applications and is the most flexible arc
spray machine. Suited to hand held or robotic mounting, it is as happy spraying 1.6mm engineering wires onto
shafts as it is spraying 2.3mm corrosion coatings onto steel fabrications. The system has undergone a rigorous
design, engineering and testing program to bring you a high quality, medium capacity but flexible system that will aid
you to maximise production, efficiency and productivity in your thermal spray operations.

Key features

 New S245-CL or S345-CL sealed energiser = reliability

 Contact tubes/tip = fine coating, long life
 Digital displays = clear, robust with wide viewing angle
 Closed-loop current = simplicity / reliability
 Uses wires from 1.6mm to 2.3mm
 Air cooled cables = lightweight
 Excellent pistol manoeuvrability
 5,10 and 20m supplies packages
 Anti-corrosion and engineering coatings
 Easy to maintain = lower downtime
 5m pull option available for small workshops
 MIG and drum dispense
 Soft start for smooth start ups = reliability
 PTFE lined conduits = reliable long wire feed

ARC170/AC-CL
The ARC170AC arc spray variant has been developed with air cooled cables for a lighter hand-held pistol weight
when spraying at 700A. The use of air cooled cables, as well as some other pistol modifications have reduced the
hand held weight by about 2kg – a significant benefit to the spray operators.  Feedback from users of the existing
700A push systems is that the pistol is less restricted in movement and lighter than the systems that they are used to.
This, combined with the ability to have 10m push/pull and even longer extended supplies systems is making the
ARC170AC a great solution for large scale anti-corrosion applications. As an additional development, the drive motor
is now a powerful brushless AC motor with inverter control.

The Metallisation ARC170AC offers high throughput with large diameter wires of 1/8” / 3.2mm and 3/16” / 4.76mm,
and is the recommended system for large scale, anti-corrosion applications.  The ARC170AC's proven and
patented Synchrodrive push/pull system has no motor in the pistol, resulting in a lighter, more maneuverable hand-
held spray gun which has a 10m wire dispense distance.  The system's robust design also includes the established
Constant Geometry (CG) head, which ensures a smooth and consistent spray quality.

The new S700CL, 700 amp energiser still offers high spray rates for reduced spraying times over large areas but is
now combined with closed loop current control.  This enables the operator to set the spray current independent of
wire type before starting the job, enabling easier setup and protection of the system from over-current.  The control
function is now controlled by a simple PLC which ensures improved reliability as less component parts are
required.  It also makes fault finding simple using a standard multimeter with the I/O for the PLC.

The S700CL energiser also features sealed electronics for excellent reliability in the harshest of spray
environments.  The design also allows for multiple customer-specific packaging options for the wire drive and
dispense.  In one option, for example, the unit is neatly mounted on the energiser, leaving it free to swivel and follow
the operator when spraying.  Other options include floor or trolley mounting of the wire drive unit.

Key features
  10m wire drive = great spraying range
 10/15m supplies extension options
 700A, 100% duty cycle = reliable
 Closed loop current = simplicity / reliability
 3.17/4.76mm wires = high throughput
 Air-cooled cables = lightweight / flexible
 Flexible pistol movement
 Easy to maintain = lower downtime
 MIG, hardboard reel or Drum dispense
 Zinc, Alumininium or Zinc/Aluminium alloy

ARC701-CL
The Metallisation Arc701-CL twin wire arc spray system is a unique blend of ability and innovation. It brings
together the proven performance of our Arc700 pistol plus the very latest technological advances. For instance,
the 700A energiser still offers high spray rates for reduced spraying times over large areas but is now combined with
closed loop current control. This enables the operator to set the spray current independent of wire type before starting
the job, enabling easier setup and protection of the system from over-current. 

The control function is now controlled by a simple PLC which ensures improved reliability as less component parts
are required. It also makes fault finding simple using a standard multimeter with the I/O for the PLC. The S700CL
energizer features sealed electronics for excellent reliability in the harshest of spray environments. 

The design also allows for multiple customer-specific packaging options for the wire drive and dispense. In one
option, for example, the unit is neatly mounted on the energiser, leaving it free to swivel and follow the operator when
spraying. Other options include floor or trolley mounting of the wire drive unit.

The drive unit is very robust, ensuring supreme reliability in the most arduous of site conditions. The lightweight,
hand-held pistol incorporates proven Metallisation technology, including a unique, constant geometry (CG) head.
This ensures smooth and consistent spray quality and minimal downtime when changing consumable spares.
Various packaging options, including an extended site trolley, allow the energiser to be sited up to 25m from the
pistol spraying area. Alternatively, the drive unit can be mounted neatly on the energiser, leaving it free to swivel
and follow the operator when spraying.

Key features

 Closed-loop current = simplicity / reliability

 New sealed energiser = reliability
 High throughput = less spray time
 Easy to maintain = lower downtime
 Uses wires from 2.3mm to 3.17mm
 Push system
 Drive to pistol distance = 5m
 Energiser to pistol distance up to 25m
 Designed and suited for anti-corrosion applications
 Lightweight pistol
 Robust design = greater reliability
 Wire dispense from reels, coils or drums

ARC528
The Metallisation ARC528E-ICC arc spray systems, with either the 250 amp or 350 amp energiser, offers the
ultimate in reliability and precision for demanding production applications. This includes both anti-corrosion and
engineering coatings. Wire drive is supplied at the heavy-duty pistol by a highly accurate, powerful DC servo motor,
driving a robust gearbox and drive roller system. 

The high performance pistol incorporates proven Metallisation technology, including a unique constant geometry
(CG) head. This ensures smooth and consistent spray quality and minimal downtime when changing consumable
spares. 

A new addition to the 528E system is the quick release supply package option. To further reduce machine downtime,
the supplies package can be chosen with a quick release option, enabling the pistol to be removed quickly from the
line and either maintained or exchanged for a spare pistol for preventative maintenance routines. 

The PLC controlled energisers enable the operator to set the spray current independent of wire type before starting
the job, enabling easier setup and protection of the system from over-current. The control function is now controlled
by a simple PLC which ensures improved reliability as less component parts are required. It also makes fault finding
simple using a standard multimeter with the I/O for the PLC. All of the control electronics are in a sealed area of the
energiser to protect them from the often harsh, production environment. 

The 528E-ICC is offered with either the 250 amp or 350 amp energiser, depending on your production and
throughput requirements. As an alternative, a high throughput version is also offered with either 700 amp or 1000
amp energisers. 

Key features

 New S250 and S350 sealed energisers

 Closed Loop Current = simplicity / reliability
 Inbuilt pistol control system
 Integrates to production machinery
 Safety interlocks
 Anti-corrosion and engineering wires
 Easy to maintain = lower downtime
 Uses wires 1.2mm to 3.17mm
 Quick release supplies option for fast pistol changeover
 Wire dispense from reels, coils or drums

ARC340-PLC
The Metallisation ARC340-PLC arc spray system is the preferred choice for general engineering applications. It is
ideally suited to tool post and automation mounted applications with occasional requirements for hand spraying. The
proven ARC340 pistol is now combined with a new range of PLC controlled, 250A and 350A switched voltage
energisers. 

The ARC340-PLC system with a S250, 250A energiser is ideally suited to many engineering applications. However,
for some larger scale applications where a higher throughput is required, the S350, 350A energiser will enable higher
spray rates and increased productivity. The ARC340 is capable to spray anti-corrosion coatings also but may not be
the most suitable solution for these applications. Alternative, more suitable systems could be the ARC140, ARC701
or ARC170 systems. 

The PLC controller within the sealed electronics area of the energiser enables easy fault finding and offer over-
current protection for the system. This means that the system will protect itself in the event of operator error when
setting up spray parameters. The ARC340 pistol on its own supersedes and can be fitted as a direct replacement to
the ARC234, ARC240 and ARC375 pistols. With fairly minimal modifications, it can also be fitted to some competitor
pull systems.

 
Key features

 PLC controlled energisers = reliabilty

 Over-current protection
 Air driven pull system
 Air cooled or solid cables
 Easy to maintain
 Uses wires from 1.6 - 2.3mm dia. without changing feed rollers
 Choice of coating textures
 Optional Arcbeam spray concentrator
 Optional deflected spray extension sections

MEC 96/600
The MEC 96/600 system is a 3 phase, 600 amp arc spray system with 5 metre pull via a pneumatic drive in the
pistol. It can be set up to spray 1.6mm engineering wires or 2.3mm anti corrosion wires.

TMS BRIDGEMASTER
 
The TMS Bridgemaster is a heavy duty, lightweight, low energy, high deposition arcspray system for applying
metalized coatings. Designed for shop or field applications, the Bridgemaster is a proven workhorse in any
environment. Meters and controls are conveniently located on the feeder providing "at the workplace" control.
Flexibility in design allows for a wide variety of possible configurations. For shop or field corrosion control coatings,
the Bridgemaster system is a formidable package. The lightweight portability of the total system, low maintenance,
lightweight gun and leads, and the "no wire-clipping" feature add up to increased arc production time for the
applicator. Sprays 3.2mm and 4.76mm wires, wide spray pattern, powered by single phase or 3 phase inverters or
DC welding power supplies.

MSS NACE coating inspector equiped with the necessary testing equipment available for in house or on site coating
assessment.
Surface profile, Coating thickness, Dew point, Bend test, Adhesion test, QC, Failure Analysis, Coating Repair or renewal
inspection.

PROJECT MANAGEMENT
MSS provide project management services for major infrastructure projects and plant shut downs where thermal sprayed
coatings are involved. Often time crucial and involving many aspects such as material and equipment sourcing, coating
preparation, application and quality control. We provide our services to ensure the work is carried out correclty according to
specification. Credentials such as NACE Coating Inspector, Confined Space, First Aid and working at heights allow us to attend
sites such as N.Z Refinery and Methanex.
We work closely with contractors throughout New Zealand also in Fiji, New Caledonia and Tahiti.

CORROSION PROTECTION
Corrosion control using metal sprayed coatings requires the spraying of an
anodic metal in a semi molten form onto an abrasive blast cleaned surface.
This forms a metallic layer which protects steel from corrosion by both barrier
and sacrificial galvanic action. The two most commonly used materials
are Zinc, providing galvanic protection sacrificing itself in preference to the
steel, and secondly Aluminum which acts as a passive barrier. 85/15 Alloy
(85% Zinc, 15% Aluminium) incorporates the best characteristics of both
materials and is becoming widely used.
Wire stocked can be viewed here.

There is no restriction to the grade of steel or the size of the structure that can
be metal sprayed. No drying time is needed allowing either instant use or
sealers and paint systems to be applied for safety or aesthetic reasons. There
is no limit to maximum coating thickness for the structure to be coated as
with hot dip galvanizing although thicknesses above 400 micron of zinc or
250 micron of aluminium are not normally specified. Thermal sprayed coatings
are the coating of choice for severe marine splash zone and highly
corrosive environments offering the highest number of years to first
maintenance.
Refer to AS/NZS 2312 - "Guide to the protection of structural steel against
atmospheric corrosion by the use of protective coatings", or Contact us for a
recommended coating specification for your project.

Wairakei Bridge - East Taupo Arterial

New Zealand’s longest ladder deck bridge at 440m, not only is it the longest, its 10,000m2 of steel structure has a
unique coating of 11 tonnes of thermal arc sprayed pure Aluminium at 220 micron. Applied in 2010 it is the largest
application of Aluminium in Australasia and may even be the largest of its kind in the Southern hemisphere.
Aluminium provides a protective coating against atmospheric, chemical and high temperature corrosion and specified
for this project due to sulphur emissions nearby. The coating provides the NZTA with the required minimum of 35
years to first major maintenance for this steel bridge.
Te Rewa Rewa
New Plymouth’s award winning Te Rewa Rewa pedestrian and cycle bridge provides a spectacular illustration of the
capacity of engineering to combine utility with fine art. The tied arch bridge with a clear span of almost 70 metres is
part of the extension of the city’s coastal walkway. The steel work was thermal arc sprayed with 200 microns
of zinc, sealed with an epoxy primer 50 microns followed by 100 micron coat of a multipurpose off-white epoxy
coating and a white semi-gloss polyurethane.
CUI - NZ Refinery
Corrosion Under Insulation (CUI) is a severe form of localized external corrosion that occurs in carbon and low
alloy steel equipment that has been insulated. This form of corrosion occurs when water is absorbed by or collected
in the insulation. The equipment begins to corrode as it is exposed to water and oxygen. CUI is common in refineries
and process plants that typically operate equipment at high temperatures of up to 550°C. Thermal
Spray Aluminium (TSA) coatings are specified by many major oil companies and have been flame sprayed at N.Z
Refinery in Ruakaka.
 VIEW EDITORIAL

Wahine Mast
The 18 metre forward mast of the ill-fated inter Island ferry Wahine was kept by the Wellington City Council for
decades before being given to the Hutt City Council. Covered in rust and graffiti it was then restored at a cost of
$45,000. A zinc thermal sprayed coating & paint system was applied and from 2009 it stands on the coast at
Korohiwa Bay as a memorial to those lost in 1968.
Furniture
Thermal sprayed Zinc coatings for corrosion protection of steel are not only suited to large infrastructure
projects but also residential applications such as stair structures, beams and outdoor furniture. The options of
applying zinc, zinc/aluminium or pure aluminium also provide better protection compared to hot dip galvanising
especially in coastal areas. There’s also the opportunity to use different coatings, such as bronze or copper, to fit
with the overall design scheme.
Air Liquide - ISO Gas Tank Container
Impact damage caused during regular road transport and shipping combined with the high chloride environment on
vessel decks causes these ISO containers to badly corrode. Ongoing maintenance was at high cost to the company
as they were having to repair and repaint them on average once a year. MSS visited the customer to view one of
these well travelled units and saw how badly the steel was affected. We designed a coating specification of 100
micron of thermal arc sprayed 85/15 (85% Zinc, 15% Aluminium alloy) with 200 micron 85/15 over areas prone to
damage. A used ISO gas unit was provided and this coating applied along with company colours early 2011. MSS
revisited the customer several months later to see how the coating had performed. There were multiple impact
damaged areas, most with the paint system totally removed but no signs of corrosion.
Waita River Bridge
Located north of Haast and around 1 Km from breaking surf, the Waita River Bridge was abrasive blasted and
recoated in situ with 300 micron minimum 85/15 (85% Zinc, 15% Aluminium alloy) and vinyl sealer in 2006. Recent
visits to the site showed the coating was in excelent condition confirming the expected lifetime to first maintenance
of 40 years or possibly more.
ENGINEERING COATINGS
Thermal Spray technology is frequently used in engineering applications to
increase wear resistance in the life of components and also to repair crucial
parts that have worn or have been damaged. The benefits of thermal spray
coatings for metal repair and reclamation are many and varied. The major
driving factor is one of cost. With many individual parts costing thousands of
dollars, the ability to repair areas offers a major cost saving and less
downtime. Also, coatings of materials that have different properties than the
base material can be applied to provide localised increases in wear
protection.

Metal Repair - Reclamation - Restoration.

 

Waitaki Turbine Shaft

A hydro power station works by harnessing the energy from falling water. The water held above the power
station in a lake or reservoir is channeled through pipes or penstocks to the turbine. The turbine extracts the energy
from the water, turning it into mechanical energy that spins the generator rotor creating power. This turbine
shaft required a 1050mm long bearing surface to be built up. Weighing many tons and over 3.3M long this made for
a large job under tight deadlines. The shaft was mounted in a lathe, pre machined then with the aid of a mechanical
traverse a thermal sprayed bond coat was applied followed by final coat of Iron, Nickel, Chrome, Boron, Silicone
alloy, sealed and finished to fine tolerances.

Engine Parts
For either fast turn around, unavailability of new parts or as an alternative to high cost replacements, thermal sprayed
coatings are applied to crankshaft journals, cylinder head mating faces, bearing faces, hubs and shafts in the
automotive and marine industries.
Caterpillar dump trucks used in a Southland mine have a loading capacity of around 100 tons. The life-span of a rear
axle is about 13,000 hours which is equivalent to about 2 1/2 years work. The axles are expensive to replace and
difficult to obtain, so the question was - could their life span be increased? A specialist metal spray contractor from
Dunedin arc sprayed the rear axle. Due to the nature of the process, the base material of the axle was not placed
under any risk of metallurgical change during the process. After surface preparation, a bond coat of Ni - Al -
Moly was arc sprayed giving a tensile bond strength of over 7,000 psi. This bond coat was followed by a customised
alloy. After the coating was completed, the axle was machined to a fine finish and close tolerance. The first axle was
arc sprayed around 20 years ago and many other axles have been repaired to date, at a cost of $1,500 each and a
turnaround time of 13 hours. 
Yacht Propeller Shaft
The 52 Metre, 1902 schooner Shenandoah had its propeller shaft reclaimed in Auckland. To resist continuous salt
water immersion a stainless steel with boron and silicone was needed for the gland seal area. Quite often the applied
material has better performance than the original substrate.
EXTREME ENVIRONMENTS
Thermal sprayed coatings allow the application of materials to protect
substrates subjected to multiple harsh conditions in one environment.

Vessels
The digester is a special piece of machinery used in the process of papermaking. Its purpose is to chemically cook
small wood chips for several hours in order to soften them. This Kraft Pulp digester in Kawerau was originally
internally weld overlayed with 309 stainless but showed signs of cracking causing the substrate to loose 1mm
thickness per year. Replacement cost at the time was $40 million but in 1985 a plasma sprayed coating of a nickel
based alloy was applied which exceeded the expected 2 year coating life lasting to 6 years. It has since been
recoated in 1991 and 1997 and is still in operation today.
Mighty River Power
This LP Steam Demister at Mighty River Power in Kawerau had internal corrosion and erosion issues due to steam
at 140°C at 60psi containing particulates, hydrogen sulphide and hydrosulphuric acid. A coating of 400 microns
minimum of Inconel 625 stainless steel was applied in 2012.
Gas Turbines
In the aerospace industry, thermal spray coatings are used in a large number of applications for meeting high
performance levels and high quality requirements. These coatings include ceramic, metal, and composite materials.
Thermal spray coatings protect Gas Turbine blades from extreme temperatures, and ensure increased reliability for
extended periods of time. In landing-gear applications, these coatings are replacing hard chromium plating as the
preferred coating method to provide improved performance. Applications in these and other aerospace applications
may include: Landing gear (bearings, axles, pins, etc.),  Jet engines (blades, vanes, combustion liners, compressor
casings, nozzles, etc.), Actuation systems (pistons, pumps, flaps, etc.), Engine cowling, wing structures.