Thermal spraying with zinc and zinc-aluminium
The first choice for sustainable corrosion protection
What is thermal spraying?
Thermal spraying provides long-lasting corrosion protection for metal surfaces. We use metallic materials such as powders or wire, which we heat with an electric arc or flame until they melt. The molten material is then sprayed in fine form onto the surface. This creates a uniform and strongly adherent protective layer that is robust and resistant to external influences.
Our specially developed zinc alloys ensure reliable corrosion protection and consistent coating thicknesses with strong adhesion. The process is suitable for many applications – from bridge renovation to industrial projects.
Our experts ensure quality at every step. They optimally prepare the materials and develop appropriate protection concepts. This way, we prevent damage and promote sustainable, environmentally friendly solutions.
GRILLO offers you everything from a single source – from development to implementation. Our products are recognized as market-leading. Efficiency and environmental protection are always at the core of what we do.
How long has thermal spraying been around?
Thermal spraying has been used worldwide as reliable corrosion protection since the 1950s. Since then, the process has proven itself in many areas especially in bridge and steel construction.
However, the technology itself is even older. It was developed and patented at the beginning of the 20th century. Over the years, processes such as wire flame spraying, arc spraying and plasma spraying have further improved it and made it more versatile.
The first major thermal spraying projects were carried out in the USA and the UK. In the USA, experts used the process to protect against corrosion, for example on large water tanks and tuna fishing boats. They also used it on chemical tanks, rail tank cars, pipes and condenser housings.
Norway went one step further, since the 1960s, the method has been required by law for all bridges near the sea. The Benelux countries have also been using it successfully in road and railway construction since the 2000s.
In Germany, the method is not yet fully integrated into the legal framework. Nevertheless, it is being used for example for the Grevenhof lock bridge. This shows how effective and sustainable thermal spraying is when it comes to protecting steel structures.
The Technology is used in many other industries in addition to the construction industry. These include, for example, aviation, mechanical engineering, energy technology and medical technology.
What are common alternative technologies to thermal spraying?
As alternatives to thermal spraying, there are hot-dip galvanizing and paint coatings. In hot-dip galvanizing, the metal is immersed in molten zinc to form a protective layer. Paint coating involves applying a protective paint to the surface to guard against corrosion.
The benefits of the thermal spray process compared to hot-dip galvanising & colour coating
Sustainability
Thermal spraying avoids the use of chemicals and solvents, making it an environmentally friendly alternative to paint coating and reducing environmental impact.
Cold process
The cold process of thermal spraying preserves the dimensional stability of components and is gentler on the original material compared to hot-dip galvanizing.
Highly effective corrosion protection
By using more effective alloys in thermal spraying, outstanding corrosion protection results can be achieved regardless of the material, unlike paint coating.
Self-healing effect
Thanks to the material quality and dense structure, small damages can self-heal, increasing longevity, as opposed to paint coating.
Maintenance-free for up to 100 years
The robust coating ensures long-lasting corrosion protection without the need for extensive regular maintenance, unlike paint coating.
No drying time
The coated components can be processed immediately without waiting for drying times, unlike paint coating.
Logistics & transportation
Unlimited component dimensions
In contrast to hot-dip galvanizing, thermal spraying allows for the coating of components of any size, without limitations.
Versatility of steel types
Any type of steel can be protected using thermal spraying, and duplex systems allow for easy integration of paint coatings, which is not possible with hot-dip galvanizing.
Reduced downtime
Thermal spraying requires less time for drying and cooling compared to hot-dip galvanizing, reducing production downtime
Inventory availability & delivery reliability
Due to direct application, components can be stored and delivered immediately without waiting for cooling, unlike hot-dip galvanizing.
UV-resistant & paintable
The coating is UV-resistant and can be painted over immediately, allowing for further customization, unlike hot-dip galvanization.
Recycling & reduced waste
Overspray during spraying can be recycled, resulting in less waste and reduced environmental impact, unlike hot-dip galvanizing.
Free of microplastics
Immediately paintable
The ability to paint immediately allows for the immediate processing of coated components, unlike hot-dip galvanizing.
Thermal spraying in practice
Thermal spraying –
The first choice for many applications.
Further topics
Center of Excellence (CoE)
KKS-Beton
Anodes
GRILLO zinc-aluminium – the solution for tough cases
GRILLO solutions for corrosion protection
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Talk to us today about the benefits of this highly effective and sustainable application technology.
Stefan Hof
