Chettinad Cement Corporation, Ariyalur
A chimney taken from bare-metal blasting through to its aluminium coating by one team, as a single system.
Corrosion Protection in Chennai
We protect steel at Chennai plants as a single system comprising blasting, zinc or aluminium metal spray, sealer and paint, chosen for the asset.
- Paint, zinc, aluminium or duplex
- One contractor from blasting to final coat
- Aluminizing expected to last 10 years or more
Protection Systems for Chennai Assets
Steel in a Chennai plant does not all require the same protection. A frame inside a factory shed at Sriperumbudur or Oragadam and a boiler chimney near the coast face very different duty, and each needs its own system.
For dry, covered steel, blasting to Sa 2½ with a primer and paint system is often sufficient. For steel that stands outside or in process fumes, thermal spray zinc with a sealer provides sacrificial protection that paint alone does not. For steel that runs hot, such as chimneys and flue ducts, we use thermal spray aluminium.
For steel near the Chennai coast or in aggressive process air, paint over the sealed metal coating adds colour and extra life. This is a duplex system, in which the metal protects the steel and the paint protects the metal.
Assets We Protect in and Around Chennai
Boiler and DG chimneys, flue ducts
Heat and acidic flue condensate cause paint to fail early, so chimneys and ducts are blasted and aluminized, usually in place during a shutdown.
Chemical and process plants, north Chennai
Pipe racks, tank exteriors, gutters and platforms outdoors, where zinc with a sealer and paint on top is a common duplex route.
Towers, transformer tanks and bridge steel
Communication towers, transformer tanks and radiators, bridge girders and pipelines, where the steel is too large for a hot-dip bath or is already standing.
Factory and warehouse steel, Sriperumbudur, Oragadam and Ambattur
Platforms, pipe racks, conveyor frames and equipment inside sheds, where blasting and a paint system with DFT checked on every coat can be sufficient.
How We Specify and Apply a System
We begin with the asset, considering what the steel is, where it stands, how hot it runs and how long you require before the next shutdown. We then recommend one of the routes in the table, or follow the system your consultant or paint supplier has already specified. Structures are treated at your site by a team from Bengaluru, and components can be sent to our units.
Mythri Metallizing carries out every layer, so there is no hand-over between a blasting contractor, a metallizing contractor and a painter. Metal spray needs no curing, so the full thickness is applied in one shift. Test reports for surface profile, thickness, adhesion and paint DFT are supplied with the project.
- System routes
- Paint only · zinc · aluminium · metal plus paint (duplex)
- Zinc
- 99.95% wire · IS 5905 · IS 6586 · BS 5493
- Aluminium
- 99.5% wire · IS 2590 · BS 2569 · BS 1475
- Metal spray thickness
- 175–200 µm standard, up to 500 µm possible
- Paint application
- Airless and compressed-air spray, DFT checked on every coat
- Test reports
- Surface profile, thickness (IS 3203), adhesion (ASTM D4541), DFT
Chimney Work in Tamil Nadu
JKPL, Tamil Nadu
Thermal spray aluminium on a boiler chimney, the kind of asset where heat and flue condensate cause paint to fail early.
Frequently Asked Questions
How should we choose between paint, zinc, aluminium and duplex?
Paint over blasted steel suits dry, covered steel. Zinc with a sealer suits outdoor and structural steel. Aluminium suits hot surfaces, chimneys and marine or chemical service, and is expected to last 10 years or more. Duplex adds paint over either metal. If you share the asset and its duty, we will recommend one.
What does paint add over metal spray?
Colour, a smoother surface and extra life in aggressive air. The metal coating protects the steel and the paint protects the metal coating, so the system outlasts either layer alone. On hot surfaces the paint must be rated for the temperature.
Must we write the system ourselves?
No. If your consultant or paint supplier has a specification, we follow it. If not, we recommend a system from the environment and the design life, which you may verify with your own consultant.
Which reports do we receive?
Test reports for surface profile, coating thickness, adhesion and paint dry film thickness are supplied with the project. Metal spray thickness is measured with a calibrated gauge before the work is released.
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.