Zinc Arc Wire Spray Coating in Auckland
Heavy-duty corrosion protection for marine, structural steel, and infrastructure applications. Long-lasting protection in New Zealand's harshest environments.
Get A Free QuoteWhat is Zinc Arc Wire Spray?
Zinc arc wire spray, also known as thermal spray metallising or zinc metallising, is a process where zinc wire is melted using an electric arc and sprayed onto prepared steel surfaces. The resulting zinc coating provides sacrificial corrosion protection - the zinc corrodes preferentially, protecting the underlying steel even if the coating is damaged.
This process is the gold standard for corrosion protection in demanding environments. It's widely specified for marine, coastal, industrial, and infrastructure projects where long-term durability is essential.
How Zinc Metallising Protects Steel
- Sacrificial Protection: Zinc corrodes instead of steel, even at scratches or damage
- Barrier Protection: Dense zinc coating physically blocks corrosive elements
- Self-Healing: Zinc corrosion products help seal minor damage
- Long Service Life: 50+ years protection in many environments
- No Maintenance: Unlike paint, zinc metallising doesn't need regular recoating
Applications
- Marine Structures: Wharves, jetties, boat lifts, marine hardware
- Coastal Buildings: Structural steel in salt spray zones
- Infrastructure: Bridges, transmission towers, pipeline supports
- Industrial: Processing equipment, tanks, structural steel
- Mining: Conveyors, hoppers, structural steel
- Water/Wastewater: Pipe supports, walkways, platforms
Zinc Metallising vs Hot-Dip Galvanising
Both processes provide zinc protection, but zinc arc spray offers several advantages:
- No Size Limits: Can coat items of any size (hot-dip limited by bath size)
- No Heat Distortion: Steel isn't immersed in molten zinc
- Variable Thickness: Coating thickness can be controlled to specification
- On-Site Application: Can be applied in the field
- Touch-Up Capability: Easy to repair damaged areas
Our Process
- Surface Preparation: Sandblasting to white metal (SA 2.5 or SA 3)
- Metallising: Zinc wire melted and sprayed to specified thickness
- Sealing: Optional sealer applied to fill porosity
- Topcoat: Optional paint topcoat for aesthetics or additional protection
- Inspection: Coating thickness and adhesion verified
Specifications & Standards
We work to recognised standards including:
- AS/NZS 2312 - Guide to the protection of structural steel against atmospheric corrosion
- ISO 2063 - Thermal spraying metallic coatings
- Client specifications and engineering requirements
Frequently Asked Questions
Zinc metallising can provide 50+ years of protection in many environments. Even in severe marine conditions, properly applied zinc coatings provide 20-30 years protection. The actual lifespan depends on coating thickness and environmental severity.
Yes, zinc metallising is often used as a base for paint systems (duplex systems). The combination of zinc metallising plus paint provides extended protection - typically 1.5 to 2 times longer than either system alone.
Typical thicknesses range from 100-150 microns for general industrial use, up to 200+ microns for severe marine environments. We apply coating thickness as specified by engineering requirements or relevant standards.