Engineers India Ltd, ISPRL Padur, Udupi
TSAC was applied at the strategic crude oil storage facility at Padur, for a Government of India undertaking.
Thermal Spray Aluminium Coating Services
Aluminizing protects steel that operates at high temperature or stands in salt and chemical air.
- IS 2590 · BS 2569 · BS 1475
- 99.5% pure aluminium
- Engineers India approved vendor (TSAC)
How Aluminizing Protects Steel
In thermal spray aluminium coating (TSA), also called aluminizing, aluminium wire of 99.5% purity is melted in an electric arc, atomised with compressed air and sprayed onto steel that has just been blasted. The layer bonds into the blast profile and forms a dense barrier of aluminium and its oxide.
Aluminium resists oxidation and corrosion at temperatures where most paints soften and peel, and it performs well in marine and industrial atmospheres. In chloride and seawater conditions it also protects the steel sacrificially, in the same way as zinc.
Aluminium reflects and conducts heat, so an aluminized surface can also reduce heat radiation from preheater structures, rotary kilns and tertiary air ducts to some extent.
When to Specify Thermal Spray Aluminium
Chimneys and Stacks
Boiler, DG and process chimneys, where heat and acidic flue condensate cause paint to fail early.
Hot Zones in Cement Plants
Preheater towers, cyclones, kiln shells and tertiary air ducts.
Marine and Coastal Steel
Ship hulls, port structures and plants within reach of sea air.
Long Service Life with Minimal Maintenance
A properly applied TSA system is expected to last 10 years or more, so plants are shut down less often for recoating.
Specification
Thickness, sealer and any paint on top are agreed for each project on the basis of the operating temperature, the environment and the design life.
- Surface preparation
- Grit blast to ISO 8501-1 Sa 3, or Sa 2½ where specified
- Coating material
- Aluminium wire, 99.5% purity
- Application
- Electric arc spray, at our facilities in Bengaluru or in situ at your site
- Standard thickness
- 175–200 µm, measured before release
- Standards
- IS 739 · IS 2590 · BS 2569 Parts 1 & 2 · BS 1475
- Thickness test
- Calibrated gauge with test pieces, to IS 3203
- Adhesion tests
- Pull-off to ASTM D4541 and scribe test
- Sealer
- Applied to close porosity; paint top coats where specified
Our Aluminizing Procedure
Blast
The steel is grit blasted to white or near-white metal, and the profile is checked before spraying begins.
Spray
Aluminium is arc sprayed in overlapping, crossing passes to an even thickness. The coating requires no curing, so the full thickness can be applied in one shift.
Seal
A sealer suited to the operating temperature closes the pores of the sprayed layer.
Test and Record
Thickness is gauged across the surface and adhesion is tested. The results are entered in the project record and the test certificate.
Applications
We aluminize for cement, power, refinery, chemical and fertiliser plants, and for infrastructure owners.
- Boiler, DG and process chimneys
- Preheater towers, kiln shells and TA ducts
- Crude oil and product storage tanks
- Railway bridge girders
- Mufflers and exhaust systems
- Ship hulls and marine structures
- Process equipment and flanges
Recent Projects
Chettinad Cement Corporation, Ariyalur
Chettinad recorded that the work was entirely to their satisfaction in terms of speed, quality and workmanship.
Prakash Asphaltings & Toll Highways, Ratlam
Steel girders of a railway bridge on State Highway 27, Madhya Pradesh, were metallized to Indian Railway Standard specifications. The client recorded that the work was completed within schedule and that the quality of workmanship was excellent.
Frequently Asked Questions
Should zinc or aluminium be chosen?
Zinc suits most atmospheres and gives strong sacrificial protection to structural steel. Aluminium is the better choice for high temperatures, chimneys, and marine or chemical service. We recommend one on the basis of the operating conditions.
Can a chimney be aluminized without being taken down?
Yes. Chimneys are usually aluminized in situ. Our team blasts and sprays from scaffolding or other access around the chimney, usually during a planned shutdown.
How long does a TSA coating last?
A properly applied and sealed thermal spray aluminium coating is expected to last 10 years or more with minimal maintenance.
Does TSA require painting?
Paint is not required for protection. The aluminium coating and sealer form a complete system. Paint is added for colour, appearance or additional life in aggressive service, and on hot surfaces it must be rated for the operating temperature.
Is Mythri Metallizing an approved vendor?
Yes. Mythri Metallizing is an Engineers India Ltd approved vendor for thermal spray aluminium coating (TSAC).
Send a Drawing for a Metallizing Quote
Share the drawing, the coating you need (zinc or aluminium, and the thickness) and where the steel is. One of our engineers will reply with the method and a 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.