Metallization considerably improves the corrosion resistance of steel structures
28.06.2016
Deposition by metallization as interlayer between the surface and the paint sandblasted can extend the lifespan of protection systems from 10 to 30 years.
Metallization advantages:
Higher mechanical strength
Resistance to humidity and temperature variations
The resistance to corrosion increases in time, especially for metal components that stand in very aggressive environments.
Metallization - A solution for those looking ahead
The pillars, beams, gussets, masts, steel structures for bridges, halls, platforms, fences and any other metal structures deteriorate quickly when not getting a protection system suitable to cope with the problems created by corrosion, abrasion and mechanical damage aggressivness. Maintenance and repair of such components generate high costs and sometimes due to site related problems, interrupt the activity in the area.
Companies that look at processes in perspective and consider getting long term benefits began to replace the old zinc coating operations and use widespread metallization, in order to reduce expenses for maintenance and repairs.
The technology allows configuring protection system according to the stresses to which it will be subjected, which gives a superior flexibility compared to alternative methods.
Thermal spray process can be used to repair or to correct metallic zinc electrochemical or thermal surfaces.
A formula with a positive impact on the environment
In addition, waste derived from the metallization process refers exclusively to dust and it is collected automatically in filter ventilation systems, transfered to sacks and recovery units. Environmental protection is thus better secured than in case of applying other coating solutions, where waste neutralization has fewer or now recovery possibility, involving therfore higher costs and harmful actions on the environment.
Choosing the metallization equipment
Arranging a space for metallization operations can be easily done and requires only the addition of a proper ventilation system, ATEX lamps and connection to air and electricity or, respectively, to the gas supplies.
Targeted production capacity is the one that determines the size of the workshop and election of the ventilation system. Metallization equipment is configured according to the company's manufacturing necesities and the size of metal parts that are subject to metallization. Another factor underlying the choice of the proper equipment relates to the results expected from respecting the duration between the blasting process and the metallization one, and/or between metallization and painting (or sealing).
The metallization equipment can achieve minimum deposits of 0.05mm and maximum deposits of 0.40 mm in a single pass. For corrosion protection, regardless of metallization equipment that was chosen, this will not cause deformities to parts or structural changes of the base material. Metallization is not recommended only for workshops, but can also be a solution on the spot, either for producing new parts or with the purpose of executing repair works.
Virtually, any metal pieces that larger than 10 cm can be covered under advantageous conditions both in terms of costs (direct and indirect) and in terms of productivity.
Metallization is a fast learning process
Staff training for working with such equipment is easily done, especially if operators are recruited from among welders.
Protective equipment is also similar to that used for welding. The only difference is that metallization uses a special helmet which is similar to the one worn when welding in confined spaces.
Quality control
In order to insure the quality of the metallization process, it is recommended to consider the condition of the surface after sanding or the compliance dew point, which can be measured with Elcometer 319/2. In addition, it is important to take into consideration and respect the times between blasting, metallization and painting operations.
To determine the thickness of the deposited layer an Elcometer 456 can be used and to measure the adhesion itself, the Elcometer 107 might be a realiable solution.
