Hot Metal Spray
Thermal metal spray creates a tightly bonded metallic coating over correctly prepared steel. Extend asset life with zinc, aluminium and zinc-aluminium thermal spray systems engineered for demanding Australian Aggressive and corrosive environments.
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Long-term asset protection
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Workshop or on-site delivery
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Complete duplex systems
SERVICE OVERVIEW
Corrosion Protection Built for Harsh Service
State Steel Treatment provides hot metal spray – also known as thermal metal spray, metallising, zinc spraying or aluminium spraying – as a durable corrosion protection solution for structural steel and industrial assets. The process deposits a continuous metallic coating onto abrasive-blasted steel, helping protect the substrate from moisture, salt, industrial pollutants and atmospheric corrosion.
The service can be delivered as a stand-alone metallic coating or as part of a duplex system incorporating a sealer, tie coat and protective finish coat. This allows the system to be tailored to the environment, required design life, appearance, maintenance strategy and project specification.
A practical alternative for difficult steelwork
PROCESS
What Is Hot Metal Spray?
In the thermal spray process, metal wire is fed into specialist equipment and melted using an electric arc or flame. Compressed air atomises the molten metal and projects it onto the prepared steel. The droplets rapidly solidify and build a dense, adherent metallic layer without significantly heating the entire steel component, contrary to the galvanising process.
The bond is primarily mechanical, making surface cleanliness and profile critical. Correct abrasive blasting, controlled application technique and prompt sealing are central to achieving a reliable corrosion protection system.
PERFORMANCE
How the Coating Protects Steel
Sacrificial protection
Barrier protection
Stable protective films
Duplex performance
SYSTEM OPTIONS
Select the Right Metal for the Exposure
Hot metal spray is not a one-size-fits-all coating. The appropriate metal, thickness and post-treatment should be selected from the project environment, expected service life, operating temperature, geometry, accessibility and maintenance requirements. State Steel Treatment can work with the client, engineer, coating manufacturer and project specification to deliver the nominated system.
Zinc
Strong sacrificial action helps protect exposed steel at small discontinuities and damaged areas.
Commonly selected for atmospheric corrosion protection where cathodic performance is a priority.
Aluminium / TSA
Develops a durable barrier and stable oxide film, with strong performance in many marine and industrial environments.
Often considered for marine, offshore, process and elevated-temperature duties, subject to the project specification.
Zinc-aluminium alloy
Combines sacrificial protection with aluminium’s barrier characteristics.
A versatile option where the designer seeks a balance of galvanic and barrier protection.
Important: The final system and dry film thickness must be project-specific. The table above is general guidance and is not a substitute for a corrosion protection specification.
Key Benefits of Hot Metal Spray
- Long-term protection for severe atmospheric, coastal, industrial and infrastructure exposure.
- Low overall heat input and direct application to large, complex or fixed steel assets.
- The metallic layer can be inspected and sealed promptly without solvent curing of the metal deposit.
- Compatible with sealers and topcoats for appearance, added barrier performance and durability.
Key Benefits of Hot Metal Spray
- Long-term protection for severe atmospheric, coastal, industrial and infrastructure exposure.
- Low overall heat input and direct application to large, complex or fixed steel assets.
- The metallic layer can be inspected and sealed promptly without solvent curing of the metal deposit.
- Compatible with sealers and topcoats for appearance, added barrier performance and durability.
APPLICATIONS
Where Hot Metal Spray Is Used
Thermal metal spray is suited to both new fabrication and maintenance projects. It is particularly valuable where steel is exposed to salt, moisture, condensation, pollutants or difficult maintenance access – and where a long-life corrosion protection strategy is required.
Structural steel & bridges
Girders, trusses, columns, handrails and exposed steelwork.
Marine & coastal assets
Wharves, jetties, port infrastructure and salt-laden environments.
Mining & materials handling
Conveyors, frames, chutes, supports and process equipment.
Oil, gas & industrial
Pipelines, vessels, skids, plant structures and terminal infrastructure.
Water & wastewater
Treatment plant steelwork, tanks, access structures and pipe supports.
Energy & infrastructure
Transmission structures, renewable projects and heavy civil assets.
Why Choose State Steel Treatment?
Established in 1990, State Steel Treatment delivers protective coating and surface preparation services for construction, mining, oil and gas, marine, water treatment, industrial, commercial and government clients. Hot metal spray expands this capability with a metallic corrosion protection option for demanding assets and long-life specifications.
Complete service
Abrasive blasting, thermal metal spray, sealing, topcoating and inspection can be coordinated through one experienced contractor.
Quality documentation
Project-specific inspection and reporting can be aligned with the specification and client hold points.
Corrosion-focused advice
System selection is approached from the asset environment, design life and maintenance needs – not simply the application method.
Workshop and site solutions
Flexible delivery for new fabrication, large assets, shutdowns and maintenance projects.
QUALITY-CONTROLLED EXECUTION
Our Hot Metal Spray Delivery Process
A thermal spray system performs only as well as its surface preparation, application control and inspection. State Steel Treatment integrates the hot metal spray process with established abrasive blasting, protective coating and inspection capabilities to provide a complete corrosion protection package.
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Project review and system selection
Confirm the substrate, exposure, design life, access, metal, thickness, sealer and topcoat requirements.
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Surface preparation
Remove contaminants and abrasive blast to the specified cleanliness and angular profile. Spray promptly to minimise flash rusting or contamination.
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Thermal metal spray application
Melt metal wire by arc or flame, atomise it with compressed air and build a uniform coating using controlled passes.
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Sealing and topcoating
Apply a compatible sealer promptly. Add a tie coat and finish coat where the specified duplex system requires them.
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Inspection and documentation
Verify preparation, conditions, thickness, visual finish, adhesion and repairs against the inspection and test plan.
VERIFICATION
Inspection and Quality Assurance
Inspection requirements are established through the project specification and inspection and test plan. Depending on the scope, quality records may include:
- Surface cleanliness and abrasive blast profile measurements.
- Ambient temperature, steel temperature, relative humidity and dew-point records.
- Metal feedstock traceability, equipment settings, visual examination and coating thickness measurements.
- Adhesion or bend testing where specified, plus sealer/topcoat thickness, cure and repair records.
FLEXIBLE PROJECT DELIVERY
Workshop and On-Site Capability
State Steel Treatment can coordinate hot metal spray with abrasive blasting, protective coatings and independent inspection requirements. Work can be planned for workshop fabrication, large components and controlled on-site maintenance scopes, subject to access, containment, ventilation, environmental controls and project safety requirements.
Standards-based delivery
Protect Your Steel with Hot Metal Spray
Speak with State Steel Treatment about a project-specific thermal metal spray system for your asset.
Address
24 Tattersall Road, Kings Park NSW 2148
Phone
(02) 9622 5544
Office Hours
Mon - Fri: 7:00am - 2:00pm Saturday by appointment
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