Chettinad Cement Corporation, Ariyalur
Chettinad recorded that the work was entirely to their satisfaction in terms of speed, quality and workmanship.
Corrosion Protection in Kalaburagi
Mythri Metallizing protects steel at Kalaburagi cement plants as one system: blasting, zinc or aluminium metal spray, sealer and paint, chosen zone by zone.
- Metal spray plus paint, as a duplex system
- Zinc to IS 5905, aluminium to IS 2590
- Test reports with every project
Coatings for Each Cement Plant Zone
A cement plant is not a single corrosion environment. Preheater towers, cyclones, kiln shells, tertiary air ducts, clinker coolers and chimneys run hot. Conveyor galleries, silos and structural steel stand in a hot, dry climate, with a monsoon season and alkaline dust on every surface.
We use that distinction to choose the system. Hot structures are usually aluminized, and aluminizing on preheater structures, kilns and TA ducts can also reduce heat radiation to a certain extent. Cooler structural steel is protected with thermal spray zinc and a sealer, or by a paint system alone where the design life allows.
Where the environment is aggressive, paint over the metal spray adds colour and extra life. Mythri has worked at the Vicat Sagar cement plant near Kalaburagi. It has also worked on cement projects in Ariyalur, Tamil Nadu, including Dalmia Cements, completed in 2025–26.
Applications Around Kalaburagi
Cement plant hot zones
Preheater structures, kilns and TA ducts receive blasting, aluminizing and sealer. Clinker coolers and chimneys receive a system agreed from the operating conditions.
Cement plant structures and handling
Conveyor galleries, silos, hoppers and steel frames receive thermal spray zinc or a paint system, chosen for the design life required.
Power plants
Boiler and DG chimneys take thermal spray aluminium. Structural steel and pipe racks take zinc, paint or both.
Dal mills and agro-processing
Silos, storage bins and structural frames receive blasting and a paint system, or zinc where a longer life is wanted.
How We Scope a Protection Project
We begin with the zone, the condition of the steel and the design life you require. We then propose a system covering blast grade, metal spray, thickness, sealer and paint. Where you or your consultant already have a specification, we follow it.
One contractor blasts, sprays and paints, so that each section is coated before it can rust. Metal spray requires no curing, so the full thickness can be applied in one shift. Thickness and adhesion are tested and reported for every project.
- System options
- Zinc, aluminium, or paint alone
- Standard metal spray thickness
- 175–200 µm, measured before release
- Standards
- IS 5905 · IS 2590 · BS 2569 · ISO 8501-1
- Thermal spray arc rectifiers and guns
- 15 sets
- Airless spray units
- 5 sets with pressure pots
- Tests
- Surface profile, thickness, adhesion, DFT
Work on Similar Systems
Prakash Asphaltings & Toll Highways, Ratlam
Steel girders on State Highway 27, Madhya Pradesh, protected with aluminium metal spray and a three-coat paint system.
Frequently Asked Questions
How do you choose between zinc, aluminium and paint?
The choice is made from the surface temperature, the atmosphere and the life required. Aluminium suits hot surfaces and chimneys. Zinc suits most structural steel. Paint alone suits less demanding service. We confirm the choice against your specification.
Is paint required over the metal spray?
Paint is not required for protection. The metal spray and sealer form a complete system. Paint is added for colour, appearance or extra life in aggressive service, and on hot surfaces it must be rated for the temperature.
How long will aluminizing last at a cement plant?
A properly applied and sealed aluminizing system is expected to last 10 years or more. Life also depends on the operating conditions, so we agree the design life with you before choosing the system.
Can all of this be carried out at our site?
Yes. Blasting, arc spray and airless spray equipment travel with the team from Bengaluru, about 570 km away, and structures are coated in place. The same work can also be undertaken at our facilities in Bengaluru.
What test reports are supplied?
Blast profile, coating thickness and adhesion results are recorded for each project, together with dry film thickness for each paint coat. Reports are supplied with the project.
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.