TSA on SLP offshore oil platform

A video showing Flame Spray TSA used on an offshore platform

Metallisation MK73 flame spray systems being used to apply thermal spray aluminium (TSA) to an offshore oil platform for corrosion prevention. The platform is destined for the North Sea. Long supplies packages (30m) were used to enable sprayers to move easily around the structure and increase productivity.

Flame spray TSA onto offshore oil platform with metallisation MK73 systems, the area of TSA was approximately 1,000 sqm to 250-400 microns.

The system allowed 30m of supplied from gas the flexibility to spray areas of 27m of long main column tubulars.

TSA footbridge

Video of a MK73 Flame Spray being used on a Footbridge

Video of Thermal Spray Aluminium being applied to footbridge with MK73 flame spray.

Metallisation MK73 flame spray systems are used to spray aluminium (TSA) as a corrosion protection coating to a footbridge for a railway crossing.

A MK73 flame spray being used on a footbridge formed of two 12 metre stair sections and a 20 metre long main bridge deck and support columns.

Aluminium coating specification

Blast to SA3, 70-100 Micron profile.
Thermal Spray Zn or Al to 100 Microns minimum Dft.
Epoxy Sealer, maximum 25 Microns Dft.
Primer and top coat to suit the final installation.
TSA applied with MK73 Flame Spray system.

TSA (Thermal Sprayed Aluminium) for CUI

The video shows the preparation and application of Thermal Spray Aluminium (TSA) to protect pipelines and vessels against atmospheric corrosion and Corrosion Under Insulation (CUI).
This clip illustrates the complete process of applying Thermal Sprayed Aluminium to deliver effective corrosion protection or an (estimated) 20+ years.

After the Thermal Spray Aluminium has been applied, the blast profile is measured and saved to be used in an audit at a later date. Next, the site is inspected with a 10X illuminated magnifying glass to check if the blast surface is clean and to identify any embedded grit particles. After this, the area is tested using dust contamination tape by placing the tape onto the surface, removing and then inspecting with a 10X magnifier.

A salt contamination test is then carried out to inspect the presence of salt on the blasted area. This is achieved through the application of an agitate test solution, then using the test pipette to ascertain the level of salt.

Afterwards, check the bond strength and thickness meets specification.

TSA is applied by the flame spray process using a Metallisation MK73 system with long supplies package to assist in accessing hard to reach areas.

Parkol Marine spray zinc onto fishing boat with ARC150

Parkol Marine Engineering, based in Whitby, has recently applied a thermal sprayed zinc coating using a Metallisation ARC150 arc spray system to a new whitefish trawler, the Resilient LK195, to protect it from corrosion.

LPG cylinder metal spraying

This video shows the automated zinc spraying of gas cylinders (LPG cylinders) with Metallisation ARC528E automated arc spray systems. This can be onto brand new cylinders or on reclaimed/repaired cylinders. The zinc coating is applied to give longer corrosion protection to cylinders compared to paints alone. The paint or powder coating are often damaged during manual handling and the zinc coating beneath provides a sacrificial coating.

Leading the Battle Against Rust

Examples of corrosion protection with both ARC and Flame Spray Systems on a variety of substrates.

Typical Applications

TSZ of wind towers with ARC528E/S1500.
TSA on offshore oil platform.
TSZ of wind towers with ARC140/S350.
TSZ of ship with ARC150/S500.
TSZ of fishing boats with ARC150/S500.
TSA for corrosion under insulation with MK73.
Spraying with the Flame Extension.
TSA of footbridge with MK73.
Typical equipment set-up – Flame.
Typical equipment set-up – ARC.

Forth road bridge coating

The Forth Road Bridge (not to be confused with the Rail Bridge) was coated by Metallisation in the early 1960’s with zinc metal spray. This video shows some extracts from a longer video unearthed from the Metallisation archives.

A coating survey undertaken over the last couple of years showed very good levels of corrosion protection still in place, some 45 years + after the opening of the bridge in 1964.

ERW tube mill weld repair

Metal spraying is used to repair the weld seam area of ERW tubes and sections. Zinc, Aluminium or Zinc/Aluminium alloys are typically sprayed using the Metallisation ARC528E automated arc spray system. Pistols are mounted with extraction boxes to extract dust and fume. For some applications, flame spray systems are also used.

Car body repairs

Metal spraying car body panels with zinc to repair corrosion, dents and seams with Metallisation MK73 flame spray system. Process as used by VW Vanshack

Auto application of thermal spray zinc to wind towers

Thermal spray zinc coating applied to a new design of shell wind tower.

Metallisation ARC528E systems with 1500A energisers are robot mounted to produce high volume, high quality repeatable coatings to give corrosion protection and increase bolt joint friction.

The 1500A systems enable high production rates required to keep up with the demand for this unique design of wind tower.