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How it works.
Technological process.
1
Grit blasting
The steel structure is cleaned and prepared by grit blasting, achieving the necessarry surface roughness of the substrate desired by the procedure.
2
Metallisation
The desired layer thickness of the choosen metal alloy is built up on the prepared surface. The alloy is choosen for the type of application.
3
Finishing
The metallised surface is coated with a high-performance paint system for further protection. This step is optional but usually recommended.
Grit blasting
Removing all the oxidized and contaminated layers of the metal
The first step in our process is the removal of all contaminated layers of the steel object. Contamination can be remains of grease, oil or oxidized layers of metal, in other words, rust.
We achieve this by the application of grit blasting. During the process a stream of abrasive material is propelled forcibly against the metal surface. This operation leaves a completely contamination-free surface behind and on the other hand prepares the metal for the next step by increasing the surface roughness to achieve optimal bonding characterestics.
Thermal Spray Metallisation
Zink (Zn), Aluminium (Al) and their alloys (Zn/Al 85/15 %) or so called Pseudo-alloys are utilized to form an anti-corrosive coat on the base metal surface. This way we prevent further corrosion by permanently blocking the way of various corrosive agents to the base metal.
We carry out the metal coating with a Flame Spray ( operated with the help of gases ) or with an Arc Spray ( electric arc operated) equipment depending on the nature of application. Both tools are designed to melt and deliver the choosen metal alloys to the target surface.
The metals are "atomised" on 3-6000 Celsius then blasted with the help of high pressure air at the previously cleaned and prepared steel surface. The surface cools down in a very short time and can be handled with bare hands. The extremely high bonding strength(8-31 MPa), anti-corrosive metal coating is formed without a heat shock, often an issue with conventional galvanization techniques.
The typical layer thickness of 100-300 micron of the metal coat grants 20-40 years of anti-corrosive lifespan for the treated steel surfaces even in the harshest corrosive environments.
Finishing
Typically with the industrial paint system from Tikkurila
The anti-corrosive coating formed by metallisation has a microporous surface. We use an epoxy based filler to prime the surface and fill up the pores. The resulting metal/paint composite layer has extremely good anti-corrosive characteristics.
For the second, final layer we mostly use UV resistant, PU, polyurethane coatings in any desired RAL color. The role of the final layer is to maximise the anti-corrosive lifespan and aesthetic experience.
There is no need for additional layers as opposed to other conventional anti-corrosive technologies.
