Thermal metal spraying and galvanizing with no size limit.

Using thermal metal spraying, we apply zinc, aluminium or Zn/Al alloy coatings to steel structures, whatever their size. We work in our plant in Pétfürdő or on site, and after metal spraying we paint the structure in the same place.

When is metal spraying better than hot-dip galvanizing?

• When the structure is too large to fit into a galvanizing bath.
• When the part cannot withstand the 450 °C heat of the zinc bath: metal spraying involves no thermal shock, so there is no distortion.
• When painting is needed on top of galvanizing: we do both in one plant, in a single workflow, which makes it more cost-effective.
• When only part of a surface needs protection, or a defectively hot-dip galvanized structure needs repairing.
• When the structure cannot be moved and has to be galvanized on site.
• In aggressive industrial, chemical, coastal or chloride-laden environments, where aluminium or Zn/Al coatings last longer than hot-dip zinc.
• For steel castings and certain iron alloys that cannot be hot-dip galvanized.
• For structures exposed to high temperatures: metal-sprayed surfaces can withstand up to 500–700 °C.

How the coating is applied

1. Grit blasting with electro-corundum to Sa 2.5–Sa 3 cleanliness, with the roughness required for adhesion.
2. Metal spraying with Arc Spray or Flame Spray equipment: compressed air atomises the molten metal onto the surface, where, without thermal shock, it cools until hand-warm and builds up into a solid metal layer.
3. Painting: the metal-sprayed surface can be painted immediately, and the primer penetrates the metal layer.

Typical coating system: at least 100 µm of sprayed metal, 20–50 µm of primer and 50–70 µm of topcoat. The metal layer can be built up to 400–800 µm as required, with a bond strength of 8–31 MPa. Metal spraying is governed by EN ISO 2063, surface preparation by EN ISO 8503 and paint systems by EN ISO 12944. More about the technology

Metals and alloys

• 99.99% zinc
• 99.5% aluminium (TSA)
• Zn/Al 85/15 alloy, combining the advantages of both metals
• Copper and special alloys (Inconel, Hastelloy) on request

References

• Railway bridges, Óbuda (MÁV, 2013) – aluminium metal spraying of approx. 350 tonnes of steel main girders for a C5 environment, a first in Hungarian bridge building.
• Wind turbine transport frame (Siemens, 2017) – at least 250 µm of zinc or aluminium for sea transport.
• Oil rig mud tank (2015)
• Military vehicle chassis (2015) – metal layers thicker than 250–350 µm.
• Truck and trailer chassis (ongoing since 2012)

Frequently asked questions

Is there a size limit for metal spraying?

No: steel structures of any size can be treated, regardless of their weight or shape. There is one limitation: metal spraying cannot reach the inside surfaces of hollow sections.

Can galvanizing be done on site?

Yes. We can bring the technology to your site, provided the technical conditions for the work can be met.

Do you have to wait before painting after metal spraying?

No, the metal-sprayed surface can be painted immediately. The primer penetrates the metal layer and further improves the corrosion protection.

Can a hot-dip galvanized structure be repaired?

Yes. The standard specifies metal spraying as a repair method for hot-dip galvanized structures, so the defective part does not have to be remanufactured.

Which is better: hot-dip galvanizing or metal spraying?

Both are good; the job decides. In aggressive environments – urban, industrial, chemical, coastal or high-temperature – metal spraying can offer better protection.

Request a quote

Tell us the size and weight of the structure and where it will be used, and send us a photo or drawing of it.

Our other services

• Cantilever gate manufacturing
• Chassis protection, vintage cars
• Heritage railings and wrought iron restoration
• Anti-slip coating
• Industrial corrosion protection (TSA, CUI)