Innovation Spring 2025

REGISTRANT INSIGHTS

Metallizing finds applications in various industries, including automotive, aerospace, infrastructure, and marine. It’s especially valued for its sacrificial corrosion resistance and is used to protect steel and to extend the lifespan of structures like bridges, tanks, and pipelines. NACE No. 12 is the main metallizing standard. This standard outlines the specifications for thermal spray coatings for aluminium, zinc, and their alloys and composites for corrosion protection of steel. It emphasizes the importance of selecting the appropriate materials and processes to achieve optimal protection against corrosion. Protection for corrosion Metallizing effectively protects against corrosion in various environments, classified under ISO 9223 Corrosion of Metals and Alloys. The effectiveness of metallizing in different corrosivity categories — from mild (C1) to extreme (C5) environments — demonstrates its versatility and effectiveness in prolonging the life of steel structures. For instance, the Association for Materials Protection and Performance (AMPP, formerly NACE) estimates it could be up to 33 years before any maintenance work is needed for metallized steel structures in C2 low-corrosivity environments such as rural areas. For C5-M very high corrosivity environments, such as coastal and offshore areas with high salinity, the metallizing longevity before maintenance would be needed is reduced to 16 years. Sealing metallized surfaces further enhances their durability. This process involves applying a sealant that penetrates the metallized coating. Sealing protection may consist of sealer application only or sealer and top coating, providing

additional protection against moisture and environmental factors. Applying metallizing The key to successful metallizing lies in meticulous abrasive blasting surface preparation to create a suitable profile for the thermal spray coating chemical and mechanical adhesion. The application of metallizing also requires precise control of the ambient conditions and spray process. Verification tests such as bend tests, adhesion strength, and dry-film thickness measurements, are essential to ensure optimal performance, uniform coverage, and suitable coating thickness.

The choice of sealant depends on the specific requirements of the application, such as environmental exposure and physical demands. Common sealing and top coatings include epoxy and polyurethane products. Based on AMPP‘s studies, a duplex system consisting of metallizing, penetrating sealer, and polyurethane would push the steel structure durability in C2 and C5-M to 39 and 22 years respectively. Submitted by: Carlos Soubrier, P.Eng., General Manager, Equadron Consultants Inc: CSA W178.2; Welding Inspector Level 3; NACE Coating Inspector Level 3.

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Innovation Spring 2025

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