MCF, Mangaluru
Thermal spray aluminium on a DG chimney at MCF in Mangaluru, a coastal plant where heat and salt air both attack the steel.
Thermal Spray Coating in Mangaluru
We arc spray and flame spray zinc and aluminium on steel at Mangaluru sites, and aluminize chimneys in place.
- Zinc and aluminium, arc and flame spray
- Aluminizing expected to last 10 years or more
- Site teams with their own equipment
Metallizing on the Mangaluru Coast
A metal spray coating protects steel without relying on a paint film, which suits salt-laden air and monsoon wetting. Zinc protects steel sacrificially. Aluminium does the same in chloride conditions and also withstands heat, which is why it is the usual choice for chimneys and exhausts.
Chimneys, ducts and exhaust systems at coastal plants take flue heat on the inside and sea air on the outside. Aluminizing is expected to last 10 years or more, so a chimney is recoated less often than with paint.
Zinc and aluminium are sprayed by arc or flame spray at your site or in our Bengaluru units.
What We Metallize Around Mangaluru
Chimneys at power and process plants
Boiler and DG chimneys are aluminized in place from scaffolding, usually during a planned shutdown.
Fertiliser and chemical plants
Ducts, stacks and vessels are sprayed on site, and worn shafts, sleeves and valve parts are sent for wear coatings.
Refining and petrochemicals
Tank shells and pipe racks are metal sprayed at the site.
Ports and shipbuilding
Aluminium is applied to marine structures and ship steel, where sea water and spray attack from every side.
Where Each Process Is Carried Out
For structures that cannot move, a team travels from Bengaluru with blasting, arc spray and flame spray sets. Steel is blasted to Sa 3, or Sa 2½ where specified, with copper slag on site, and then sprayed within hours. A sealer follows, and because metallizing needs no curing, the full thickness is applied in one shift.
Components that can be transported go to our Peenya or Dabaspet units for zinc or aluminium.
- Thermal spray arc rectifier and gun sets
- 15 sets
- Spray wire
- Zinc 99.95%, aluminium 99.5%, zinc-aluminium 85/15
- Standard thickness
- 175–200 µm, up to 500 µm possible
- Aluminium standards
- IS 739 · IS 2590 · BS 2569 · BS 1475
- Approved vendor
- Engineers India Ltd, for TSAC
Thermal Spray Work in Mangaluru
Frequently Asked Questions
Can a chimney at our plant be aluminized without being taken down?
Yes. Our team blasts and sprays in place from scaffolding or other access around the chimney. Please share its height, diameter and shutdown dates so that we can plan the crew and access.
Which thermal spray processes can be carried out at our site?
Arc and flame spray of zinc and aluminium, together with blasting, can be done on site.
How long does a thermal spray aluminium coating last?
A properly applied and sealed coating is expected to last 10 years or more with minimal maintenance. Actual life depends on the thickness, the sealer, the exposure and any paint applied on top.
What approvals and checks apply to the aluminium coating?
Mythri is an Engineers India Ltd approved vendor for TSAC. The wire is 99.5% aluminium, the coating follows IS 2590 and BS 2569, and thickness and adhesion are tested to IS 3203 and ASTM D4541.
Send a Drawing for a Metallizing 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.