Thermal Spray Applications in the Construction Industry
Construction is a wide and varied industry where there are many thermal spray (also known as metal spray) applications.
Why Steel Needs Protecting
Steel is one of the strongest and most widely used building materials in the world. From bridges and stadiums to factories and power plants, it plays a central role in keeping our built environment safe and functional. But as strong as steel is, it has one major weakness: it reacts with oxygen and moisture. Left unprotected, it rusts.
Corrosion not only spoils the appearance of steelwork but, more importantly, it reduces its strength over time. In construction projects, this can mean costly repairs, safety risks, and shortened lifespans for major assets. That’s why proper corrosion protection is essential for anyone working with steel, whether on new construction or ongoing maintenance.
Metal Spray Coatings for Corrosion Protection
One of the most reliable ways of protecting structural steel is through thermal spraying with metals such as zinc, aluminium, or a combination of both. These sprayed coatings create a physical barrier between the steel and the environment. Unlike paint systems, which can chip or peel, a sprayed metal coating bonds tightly to the steel, making it more robust in demanding conditions.
Aluminium coatings are particularly effective in marine and coastal areas, while zinc is widely used for industrial structures. Alloy coatings combine the strengths of both. The end result is a long lasting protective layer that resists corrosion and reduces the need for costly repair or replacement.
Proven Success on Iconic Global Landmarks
The metal sprayed coatings are often applied to large construction projects like the prestigious Burj Al Arab hotel. Several areas of the support steelwork were arc sprayed with aluminium (TSA) in this harsh, coastal environment to provide un-rivalled corrosion protection. The project was so successful that it became a natural choice when selecting the coatings for key structural elements of the Burj Khalifa tower that followed several years later.
Aluminium coatings are particularly effective in marine and coastal areas, while zinc is widely used for industrial structures. Alloy coatings combine the strengths of both. The end result is a long lasting protective layer that resists corrosion and reduces the need for costly repair or replacement.
Protecting Everyday Infrastructure
At the more industrial end of the sector, lighting columns, electricity pylons and farm buildings are also suitable for a metallic protective coating, applied by either flame spray or arc spray.
Protecting Internal Steelwork
It’s easy to assume that corrosion is only an outdoor problem. However, internal steelwork can also suffer damage when exposed to high humidity or chemicals. Swimming pools are a good example, where constant moisture in the air attacks the steel unless it has a suitable protective layer. By spraying zinc or aluminium onto the steel before it is installed, the problem is dealt with from the start.
Going Beyond Corrosion Protection
While corrosion resistance is the primary reason for choosing metal spray coatings, there are other benefits too. At Metallisation, we have developed solutions that add further practical properties to construction projects.
For example, our Metallisation 28E Arctec coating creates a durable non-slip surface. It has already been used in busy, safety-critical environments such as London Heathrow Airport, where baggage handling ramps and walkways needed a surface that would withstand constant foot traffic.
The same coating has been applied to ferry loading ramps and even the walkways of Tottenham Hotspur’s stadium, giving visitors and staff added confidence in slippery conditions. These projects highlight how thermal spraying can solve more than one problem at a time.
Let's Talk About Your Construction Project
Structural steelwork is a major investment, and protecting it from corrosion is vital. Whether you’re working on a landmark development, an industrial installation or a local infrastructure project – we can help you choose the right thermal spray coating for long lasting results.
If you’d like to discuss how our solutions can protect your steelwork, get in touch with Metallisation Ltd today.
Construction Example Applications
Radio / Radar / TV Masts
Reason for use: Long term corrosion protection of inaccessible objects, reducing requirement for regular inspection and maintenance. A typical example of current trends is provided by a 30.48 M (100ft) mast commissioned for the North Thames Gas Board, for installation at its headquarters.
Internal steelwork with high humidity
Reason for use: Protection of condensation corrosion in area such as swimming pools, breweries, wineries, pasteurising plants etc. The roof structure of an up-to-date dispatch department situated at the premises of ‘Frederick Robinson Breweries Ltd’ has been treated for anti-corrosive protection using one of the Metallisation systems.
Water storage tanks
Reason for use: Long Term Corrosion Protection Download PDF Go to the Process Page The photograph shows a Fylde Water Board Tower at Barnacre, near Garstang, Lancs. The tower was gritblasted to BS 4232, and then zinc sprayed to 175 microns (0.007”) followed by one coat of inhibitive sealer to