Essar Projects, Hazira
Hazira is near Surat, in south Gujarat. Essar recorded that the quality of workmanship was excellent, and found the team resourceful, competent and very co-operative at the project site.
Corrosion Protection in Ahmedabad
Steel in the Ahmedabad estates faces chemical air, dry heat and, on the coast, salt.
- Zinc, aluminium or paint systems
- Duplex systems over metallizing
- DFT, adhesion and profile reports
Protection Systems for Ahmedabad Steel
Corrosion protection is not a single coating but a choice of system for the exposure. Inland estates such as Vatva, Naroda and Sanand are hot and dry for most of the year, with a chemical atmosphere around the dye and process units. The Dahej and Bharuch coast adds salt.
In general terms, sealed thermal spray zinc suits most structural steel. Aluminium suits chimneys, hot surfaces, and marine or chemical service. Where acid or alkaline vapour is heavy, a paint system over the metal spray, known as a duplex system, does much of the work. Blasting and paint alone can suit lighter exposure or a short design life.
We confirm the choice against the chemicals present, the design life and your consultant specification, and we set the system out in our method statement before work starts.
Protection Work Around Ahmedabad
Dye and chemical works, Vatva and Naroda GIDC
Tank shells, pipe racks and structural steel in fume-laden air, where a duplex system gives longer life than paint or metal spray alone.
Pharma and process utilities
Exposed utility steel, supports and platforms, where paint over metallizing provides colour as well as protection.
Power plants and refineries across Gujarat
Chimneys, ducts, boiler structures and tank shells, where heat or process media cause paint alone to fail early.
Coastal Gujarat, Dahej and Bharuch
Tanks, pipe racks and vessels where chloride from sea air adds to the chemical atmosphere, and aluminium is often the better choice.
Protection Work at Your Plant
One team carries out the whole sequence on site. Steel is blasted section by section, metal sprayed or primed on the same day, sealed, and painted where the system calls for it. Metal spray requires no curing, so the full thickness can be applied in one shift.
Test reports for dry film thickness, adhesion and surface profile are supplied with the project. Where your consultant or paint supplier has set a specification, we apply it. Where none exists, we recommend a system suited to the exposure.
- Surface preparation
- Blast to Sa 2½ or Sa 3, ISO 8501-1
- Metal layer
- Zinc to IS 5905, or aluminium to IS 2590
- Thickness
- 175–200 µm standard, up to 500 µm possible
- Sealer and paint
- Sealer over metal spray; paint system where specified
- Reports
- DFT, adhesion and surface profile
- Aluminium system life
- Expected 10 years or more
Work in Gujarat
Frequently Asked Questions
Should a plant in Vatva or Naroda specify zinc, aluminium or paint alone?
Sealed zinc suits most structural steel. Aluminium is better for hot surfaces and heavy chemical or marine service. Paint alone suits light exposure or a short design life. Please share what the plant handles and the life required, and we will recommend a system.
What is a duplex system and when is it worthwhile?
A duplex system is paint over sealed thermal spray zinc or aluminium. The metal protects the steel and the paint protects the metal, so the life is longer than with either alone. It is worth considering where fumes, spillage or salt are constant, or where colour is required.
Can you work to our consultant or paint supplier specification?
Yes. We follow the surface preparation, coat sequence, thicknesses and recoat times in your specification or on the paint data sheet.
What reports are supplied with the project?
Dry film thickness, adhesion and surface profile results are supplied. For metal spray, thickness is gauged to IS 3203 and pull-off adhesion is tested to ASTM D4541, and the results are recorded before the project is released.
Can the full system be completed within a shutdown window?
In many cases, this is possible. Metal spray requires no curing and our teams work in shifts. Please share the dates, the area and the access arrangements, and we will plan the crew and sequence accordingly.
Send Details for a Coating Quote
Please share the structure, its dimensions and location, and your planned shutdown window. Our engineers will respond with a recommended method, schedule and quotation.
- Reply within one working day
- Drawings kept confidential
- Email acknowledgement
Thank you. Your enquiry has been received.
One of our engineers will contact you to discuss the requirement. A confirmation has been sent to your email address.