Metalock Blog – News onsite engineering services and all things metalock

March 4th, 2011

Metalock Engineering UK Ltd, BAC Corrosion Control Ltd, LSM Co Ltd announce new developments in Coating and Protection Applications

Metal spraying is a process spraying molten metal onto a surface to form a coating. This is achieved by melting either pure or alloyed metals in a flame. The molten metal is then propelled by compressed air to form a coating on the parent surface or substrate. This results in a solid metal coating upon the parent surface and the thickness of that coating depends upon the number of layers applied.

Following discussions between Metalock Engineering Ltd (Coventry) our sister company, BAC Corrosion Control Ltd (Telford) and the London & Scandinavian Metallurgical Co Ltd (Rotherham) we have now formed a working cooperation for the development, promotion and application of 2 new alloys “Prosion” and “Arctec”.

Prosion

PROSION – bridging the gap between traditional Aluminium and Zinc to protect and prevent corrosion of reinforcement bars encased within porous concrete structures.

Prosion Al-Zn-In (Aluminium, Zinc & Indium) is used in metal spraying directly onto concrete providing a long lasting membrane or layer which prevents the ingress of Chlorides through the porous concrete that results in the corrosion of the encased reinforcement bars within the concrete structure.

Prosion is a new alloy based on Aluminium and the other key components are Zinc and Indium (Al-Zn-In) which act as activators stopping the Aluminium becoming passive. This alloy is designed to bridge the gap between conventional Aluminium and Zinc and providing the following advantages:

95% of the alloy is aluminium so that the density is still only 40% that of Zinc, the alloy is harder than pure aluminium or Zinc. The combination of small amounts of Zinc and Indium keeps the alloy sacrificial in the presence of Chloride Irons.

Throughout the world there are many thousands of bridges and structures that were built before large volumes of de-icing salts were used. Concrete is alkaline in nature when first poured and the reinforcing bars do not corrode. However concrete is also porous and the chlorides seep through the concrete and begin reacting with the steel so that everything turns acid and rusting begins. The rust has a higher volume than steel and pushes out, forcing the concrete to spall off.

This can be prevented by spraying the AlZnln alloy and applying an electrical current to the reinforcing bar, ensuring the coating sacrificially protects the structure.

Arctec

ARCTEC – non slip surface traction coatings applied on site – protecting structures and people.

Metalock Engineering UK Ltd and BAC Corrosion Control combine to provide cost effective on site application that is not only preventing corrosion but providing a long lasting anti slip surface.

Metal Spraying is a long standing method for applying sacrificial coatings of either zinc or aluminium. Aluminium forms a good hard barrier but sometimes becomes passive in a mildly corrosive environment. Zinc forms a very poor barrier to erosion or mechanical damage but almost always behaves sacrificially.

Arctec is a new alloy wire which has the same corrosion resistance as pure Aluminium but it is also extremely hard wearing. This means that ARCTEC can be applied as a rough, uneven coating that is non slip on surfaces that require a high degree of friction. It is also durable and long lasting and has a high degree of wear resistance which ensures that the non slip properties remain for many years after the initial preparation. Arctec will not de-laminate even under aggressive corrosive conditions.

Spraying with Arctec provides an ideal long term solution for corrosion protection on all types of steel surfaces that require surface traction for health and safety reasons. For instance walk ways, tread plates, steps and stair cases, decks on ships and ferries, decks on offshore installations, the possibilities and applications are endless. Arctec can be applied on site, in situ by our team of highly skilled spraying technicians.

Article as featured in the British Manufacturing Plant Constructors’ Association March 2011 newsletter.